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Computer Aided Design and Manufacturing (CAD - CAM) Techniques (PDFDrive) PDF
Computer Aided Design and Manufacturing (CAD - CAM) Techniques (PDFDrive) PDF
II - - - - - - - - ---- -
October 1982
II
I I
CE T ER
- Im
~ ~ .. andNU OU
c~I
T CHNICAL REPORT
I
I-- NO. 12663 I
by A. T. AL IER IBERG,
ISILJI
D.
OSB GJ.CEVLE
The findings in this report are not to be construed as an official Department of Army position.
Mention of any trade names or manufacturers in this report shall not be construed as advertising nor
as an official endorsement or approval of such products or companies by the U.S. Government.
Destroy this report when it is no longer needed. Do not return it to the originator.
I
SECURITY CLASSIFICATION OF TtIIS PAGE (W.hon DVta Fntered)
REOTONPAGE I^ NSTRUC'IONS
REPORT DOCUMENTATION BEFORE COMPI,I.TING, FORM
1. REPORT NUMULR 2. GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER
12663
UNCLASSIFIED
115a. DECLASSIFICATION/DOWNGRADING
SCHEDULE
17. DISTRIBUTION STATEMENT (of the abstract entered In Block 20, it different from Report)
19. KEY WORDS (Continue on reverse side if necessary and identify by block number)
20. ABSTRACT (Continue on reverse side If necessary and Identify by block number)
In Phase II of this program, spiral bevel gear forging dies were designed and
manufactur'ed using the CAD/CAM technique, developed in Phase I. Three series
of forging trials were conducted. During the first series of trials, the
technological aspects of the forging procedure such as heating, lubrication,
* billet temperature and cooling were established. During the second series of
forging trials 20 gears were forged with a 0.007 inch machining allowance on
both sides of the tooth surfaces. These near net forged gears were subsequentl
20. (continued)
Page
3
TABLE OF CONTENTS (continued)
APPENDICES Page
LIST OF TABLES
10. Preform Geometry for the First Series of Trials ........ ... 28
5
LIST OF ILLUSTRATIONS (continued)
20. Measuring Forged Gear Tooth Form on Zeiss Machine ........ ... 44
6
PREFACE
INTRODUCTION
7
design and manufacturing (CAD/CAM) technology (finite element, metal forming
and heat transfer analysis) to gear forging die design and manufacture.
Gear forging dies were designed and manufactured according to the data
supplied by the output of the CAD procedure, thus, the CAD and CAM processes
were integrated. The results of the CAD/CAM techniques were evaluated for
a given spiral bevel gear/pinion set by designing and manufacturing the
forging dies via CAD/CAM. Three series of forging trials were conducted.
During the first series, the technological details of the forging procedure
such as heating, lubrication, part transfer and cooling were established.
During the second series of trials, 20 gears were produced with gear teeth
forged to near net dimensions. These gears were subsequently machined with
a single machining operation. In the third series of trials, 20 spiral
bevel gears were forged with net teeth dimensions. Thus, the gear-pinion
sets were obtained by machining only the back side of the forged gears and
by machining the matching pinions.
The project was successful in
(a) developing the details of CAD/CAM for making the
forging dies,
(b) forging gears with near net and net teeth surfaces,
(c) demonstrating the practicality and economics of
precision forging spiral bevel gears.
backside, not the teeth, of the forged gears. The matching pinions are still
to be manufactured conventionally by gear cutting. Thus, by eliminating
the tooth cutting process for the gears, which represents the costliest
operation in producing matching gear-pinion sets, considerable savings in
manufacturing costs can be expected. In addition, existing data on forged
bevel gears illustrates that forged gears are superior, in terms of fatigue
life and load carrying capability, to cut gears. Consequently, a similar
improvement in performance can also be expected from forged spiral bevel gears.
8
PURPOSE AND OBJECTIVES
by CAD/CAM techniques;
bevel gear forging dies was completed. In Phase II (the topic of this
report) the CAM techniques for manufacturing the forging dies were established
using the output of the CAD program developed in Phase I. This report
covers the details of Phase II and illustrates the integration of the CAD
BACKGROUND
conducted on gear forging in the U.S., have been sponsored by the U.S. Army.
project(1). Two major studies, one using a High Energy Rate Forging (HERF)
machine and the other using a mechanical forging press, were conducted for
there are companies in Japan and W. Germany that net or near net forge
9
Precision warm or hot forging of bevel gears is a well accepted
atmosphere to 9000 to 2,2000 F (4820 to 1,2040 C). In some cases, the slugs
flow or by placing the teeth side of the gears into a sand-graphite mixture.
Forging flash and the back side of the gears are machined by holding the
gear on the pitch line in special fixtures. A negative of the tooth form
center holes, and the forged teeth. Machined gears are inspected using
PROGRAM HIGHLIGHTS
techniques have been applied to die design and manufacture for forging
(a) rib-web type aircraft structural parts(2), (b) track shoes for military
vehicles(3, and (c) precision turbine and compressor blades(4). The ex-
10
shape forging. This approach indicates that the necessary input to the
CAD/CAM system are:
Program Outline
11
"* Phase II - Computer Aided Manufacturing (CAM) of the
forging dies (from rough billet) and demonstration of
the effectiveness of CAD/CAM by forging 20 spiral
bevel gear sets. The present report describes the
work accomplished in Phase II.
"* Phase III - Application of CAD/CAM techniques to
actual production of bevel gears (spiral or straight).
This phase has not yet started.
PROGRAM APPROACH
12
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TABLE 1. Description of Input Data Given in Figure 1
Work Position: rm, Root angle; Xbo, x, and Em, Distances described
14
bevel gears. As shown in Figure 1, the procedure begins at the design stage
where the general gear data and the blank (workpiece) dimensions are deter-
mined. Then by using a gear cutting machine (in the U.S. most of the gear
cutting machines are manufactured by the Gleason Works, Rochester, N.Y.),
the workpiece is positioned according to the work position parameters and
the cradle is set according to the cradle setting parameters. A straight-
sided tooth cutter then "generates" (both the cutter and workpiece rotate
in space) the involute (or any other) profile on the gear tooth surface.
To obtain the exact description of the spiral bevel gear tooth
geometry, it is necessary to simulate the motions of a gear cutting machine
used to manufacture spiral bevel gears (5). Figure 2 explains the 3-D
vectors and angles involved in generating the gear tooth geometry. As seen
in Figure 2, an arbitrary point, P, which lies both on the cutter face and
on the gear tooth surface, is chosen. Its location with respect to the
cutter axis is calculated in a vector form in terms of the cutter radius,
rc; cutter rotation angle, 0; distance of P from the cutter blade tip;
cutter tilt, i (with respect to cradle axis as explained in Figure 3); the
direction of tilt, j; the cradle position, g; (both lie in the machine plane
as shown in Figure 4), and the cutter blade geometry. Similarly, the position
of P is also calculated as a function of the workpiece geometry and its
orientation. Using these two vector equations, normal and tangential velo-
cities of P with respect to the cutter axis are calculated. So that P be
an actual point on the gear tooth surface, the normal velocity to both the
cutter and tooth surface at P must be zero. If not zero, the vector com-
putations are iterated upon the cradle position, q; until the normal velocity
is equal to zero, and hence a point on the tooth surface is generated. By
considering that P is on both the workpiece and the cutter and by rotating
the cutter, i.e., changing the rotation angle (0) in increments, it is
possible to simulate the gear cutting process. As a result, the points on
the surface of the gear tooth are generated.
During the forging process, both the forged gear and the dies
experience dimensional variations due to elastic deflections, bulk shrinkage
15
Y
q
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, Ccr F:
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FIGURE 2. A Simplified Isometric View of Gear Generating Machine Kinematics
16
Machine plane
; Line i
Plane containing
cutter face
17
M/C plane
Line t
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Line 3
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18
and temperature differentials. To obtain the desirable accuracy in the
forged gears, each of the geometrical variations mentioned above must be
estimated and the die geometry must be corrected accordingly. For this
purpose, Task 2 included several subtasks, as briefly discussed below.
a a
e x-V (in./in. )
x E E
and
a ax
e -- - V - (in./in.)
y E E
19
262 CDIE
63.5 30
-10750-
11020
billet, the elastic deflections can be computed from
T = ambient temperature.
etd ='d (T - T)
Thus, the overall die and gear tooth elastic deflections due to
temperature differentials (e ) can be expressed as
et = etb - etd
21
These results demonstrated that the largest component of the elastic
deflections were due to temperatures.
Early in Phase I, it was decided that "precision" forging the spiral
bevel tooth geometry to finish tolerances would be very difficult, at least
in the initial stages of the study. Therefore, a machining allowance of
0.007 inch was to be provided on each flank of the gear tooth. Thus, the
rough machining operation would be replaced by the close tolerance forging
technique while the finish machining operation would still be conducted
in the initial phase of this development program. Accordingly, the dimensions
of the electrodes, used for EDMing the forging dies, were modified to include
the following dimensional corrections:
Ar =(et + e +e) r
AZ = (e + e) Z
22
These corrections were applied to the machine settings, cutter and
blank dimensions to obtain their new values. The new values were expressed
as functions of the corrections and the old values (1) i.e.,
1) Forging conditions
2) Material properties
3) Die assembly specifications.
The material properties (e.g., flow stress, modulus of elasticity, the heat
conduction coefficient, etc.) were obtained from the technical literature.
The forging conditions (e.g., die temperature, stock temperature, lubrication,
etc.) can be obtained either from the shop floor or can be selected by the
designer, using past experience. Die assembly specifications are generally
available at the design office. With these additional input values, the SPBEVL
computer program corrects the gear tooth geometry. Using this corrected
geometry, SPBEVL calculates the blank dimensions, cutter specifications,
and the machine settings for cutting the electrode required for EDMing the
die. The electrode geometry can also be displayed on the graphics terminal
screen, if desired.
23
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Discussion of the Work Conducted in Phase II
26
3. Centering of Preform in Die. The preform was designed as
a pancake with its center lying exactly on the center of the die. This
was thought to insure even filling of the die cavity.
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placing spacers or shims between the punch and punch holder to vary the
forging and flash thickness. This is necessary because it was decided to
conduct the forging trials on a press which has a fixed bolster with no
wedge adjustment. The shims help to adjust the forging thickness and the
die fill within certain limits. The components of the die tooling set-up
are shown in Figure 13. The assembled tooling is shown in Figures 14 and
15.
32
FIGURE 14. Assembled Lower Die Holder
33
FIGURE 15. Assembled Upper Die Holder
34
Task 4. Forging Trials
35
heating and improve lubrication during forging. However, no advantage was
noted in surface finish, die fill, or forging load. The practice was dis-
continued after the initially coated billets were used.
After forging, the gears were placed teeth down, in a sand-
graphite mixture to reduce oxidation of the teeth during cooling. The
back surfaces of the gears were still exposed to air so that the cooling
rate would not be excessively slow.
During these trials, a gas furnace was used to heat the preforms.
This resulted in excessive scale formation and poor surface finish of the
forged gear teeth. The heating was done by induction in the subseauent
trials. The outside diameter of the preforms was considerably smaller than
the internal diameter of the die cavity. As a result, some preforms could
not be centered accurately and the forged teeth configurations were not
uniform.
1. The forged gear was uniform. All teeth looked almost alike.
36
This meant that the centering problem encountered
during the first forging trials was eliminated.
2. The surface quality of the forged gear teeth was
excellent. The induction heating of the preforms
produced forgings with minimal scale. That meant
that the scale problems encountered during the
first forging, trials, where a gas furnace was
used to heat the billets, were eliminated.
The net forging trials were successful in producing gears with ex-
cellent surface quality and with superior die fill, as compared to near-net
forging trials. The new preform design used in this trial was the main
reason for the better fill in the toe and heel of the gear. As shown in
Figure 12, the preform has a smaller radii in the toe and heel of the gear,
as compared with the near-net preform. This additional material in the toe and
37
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heel enhanced the filling of those parts. Figure 18 shows a picture of
the net forged gear after it was cleaned.
The results of the near-net and net forging trials are described
in detail in Appendix B.
The same nest design, shown in Figure 19, was used to machine the
back face and the bore of the net forged gear. After cleaning, the forged
gears were rolled with the cut pinions. Again, the contact pattern was
excellent.
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Dimensional Checking of Forged Gears
CONCLUSIONS
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dies, due to thermal shrinkage and elastic
deformation resulting from thermal and mechanical
loading, were also calculated and integrated into
the general computer program SPBEVL. The output
of the SPBEVL program is the new machine settings
to be used to cut the electrodes necessary for
EDMing the forging dies. The machine settings,
calculated by SPBEVL, take into account all the
previously mentioned corrections.
9 In Phase II, the main topic of this report, the
forging dies were designed and manufactured
based on the results of Phase I. Thus, the
integration and the application of the CAD/CAM
process was achieved and demonstrated. Three
sets of forging trials were conducted to close-
tolerance forge spiral bevel gears. The first
forging trials showed that uniform and scale-
free heating was necessary to obtain acceptable
surface quality of the forged gear teeth. During
the second forging trials, induction heating,
under a gas atmosphere (instead of a gas furnace
used in the first forging trials), was used for
heating the preforms. Appropriate billet coatings
and die lubricants were also selected. The results
of the second forging trials indicated that close-
tolerance forging of spiral bevel gears, requiring
only a single machining (finishing) operation
is feasible and can be implemented in production.
This would replace two machining operations,
roughing and finishing, used in conventional
manufacture of gears. The third forging trials
were aimed at producing gears with net teeth
dimensions. A computer controlled coordinate
measuring machine was used to evaluate the
47
dimensional accuracy of the forged gears. The
measurement results indicated excellent agree-
ment between the geometry of the forged gears
and the corresponding machined gears, manufac-
tured conventionally.
48
REFERENCES
1. Schultes, T., Raghupathi, P. S., Badawy, A., Altan, T., Wassel, T.,
and Chevlier, J., "Computer Aided Design and Manufacturing (CAD/CAM)
Techniques for Optimum Preform and Finish Forging of Spiral Bevel
Gears", Technical Report No. 12586, U.S. Army Tank-Automotive Command,
Research and Development Center, Warren, Michigan 48090.
3. Billhardt, C. F., Akgerman, N., and Altan, T., "CAD/CAM for Closed-
Die Forging of Track Shoes and Links", SME Paper MS 76-739, October,
1976.
7. Oh, S. I., Lahoti, G. D., and Altan, T., "ALPID - A General Purpose
FEM Program for Metal Forming", Proceedings of NAMRIC IX, SME Trans.,
Detroit, Michigan, 1981, p. 83.
49
APPENDIX A
the forging dies (e.g., preparation of the electrode; EDMing of the die,
and final finishing of the die after EDM).
From Phase I, the pressure required to forge the gear was cal-
culated to be 90,000 psi (620.5 MPa). It was also determined that the
die surface temperature would be about 1,2920 F (7000 C). This is shown
graphically in Figure 5. Using this information, a survey has been con-
ducted to select a die material which: 1. exhibits a high impact
work tool steel H-13. l) The hardness again was to be in the Rc 50-54 range.
This hardness was obtained by hardening at 1,8000 F (9820 C) with two
temperings at 1,0000 F (5380 C) followed by air cooling.
A-1
The die blanks were prepared by sawing the blank from bar stock.
The blanks were turned prior to heat treatment. To prepare the heat
treated die for EDM, the bottom of the die was ground. This was necessary
to have a qualified surface before EDM and also to remove any distortion
caused by heat treatment.
the present project, it was decided to use a gear cutting machine (not an
N/C machine) to manufacture the electrodes for the following reasons:
A-2
particles from both the electrode and workpiece, and the fluid will solidify
these particles and wash them away. As the particles wash away, the space
will become larger, to a point where the voltage cannot jump the gap. The
electrode is then advanced to decrease the gap size, and the EDM continues.
The rate of metal removal is primarily dependent on power. For a given
voltage, the higher the current-carrying capability of the equipment, the
faster the metal removal rate. The surface finish of the workpiece is
dependent on the frequency of the arcing. Many small sparks (higher
frequency) will give a smoother finish than fewer large sparks. An electrode
with a melting point substantially greater than that of the workpiece will
have a low wear ratio, whereas an electrode with a lower melting temperature
will have a higher wear ratio.
A-3
The graphite selected for the near-net tooth electrode was Union
Kostkutter 10. This electrode material was chosen because of its good
resistance to wear and it was readily available in a large round stock size.
The graphite selected for the net tooth electrode was Mor-Wear EC-15. This
material was selected because of smaller particle size and because it offers
the advantage of producing a finer surface finish in the die cavity. The
electrode blanks for both trials were turned in a lathe using normal machine
practices. The electrode blank is shown in Figure A-1.
The tooth form was cut into the electrode blank using a #28
Gleason gear generator. The settings of the gear cutting machine were
obtained from the output of the computer program SPBEVL, which was developed
in Phase I of this project. For the near-net gear, the dimensions which
were used to cut the teeth reflect a 0.007 inch (0.178 mm) machining al-
lowance on the teeth. The settings on the #28 Gleason gear generator for
cutting the near-net electrode are shown in Table A-1.
Different machine settings were used to cut the electrodes for
the net teeth, where no machining allowances were considered. The machine
settings for the net teeth electrodes are shown in Table A-2. The first
step in cutting the electrodes was the development of a finish form-cut
master set of gears. This procedure is common in developing any new set
of gears. The masters are developed by first cutting the gear. The gear
is cut to the theoretical dimensions for form, chordal thickness and spiral
angle by using a standard spread blade cutter, which cuts both sides of
the teeth at the same time. The next step is the development of the pinion.
A master gear having a thinner tooth is cut with the proper tooth form but
with a thin chordal thickness to allow the pinion to roll with the gear
on one tooth flank at a time. This allows for development of both the
drive and coast side without interference from the other side. All modi-
fications of the gear set to obtain the proper bearing, profile, and posi-
tion of bearing are made on the pinion. These developed masters are then
used as a means of checking the electrodes.
A- 4
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A- 5
TABLE A-I. Machine Setting for Cutting the Electrodes for
Near-Net Teeth Forging
BLANK DIMENSIONS
Number of Teeth 39
Pressure Angle 20D
Spiral Angle 40D
Face Angle 81D08M04S
Pitch Angle 79D50M13S
Dedendum Angle 4D14M32S
Outer Cone Distance 5.181 Inch (131.6 mm)
Face Width 1.456 Inch (36.98 mm)
Addendum 0.075 Inch (1.91 mm)
Dedendum 0.384 Inch (8.84 mm)
Distance Between Crossing
Point and Cone Apex 0.000 Inch
Mounting Distance 2.036 Inch (51.71 mm)
CUTTER DATA
MACHINE SETTINGS
A-6
TABLE A-2. Machine Settings for Cutting the Electrodes for Net Teeth Forging
Number of Teeth 39 39
Pressure Angle 20DOM 20DOM
Sprial Angle 40DOM 40DOM
Face Angle 81D7M 81D7M41S
Pitch Angle 79D49M 79D49M47S
Dedendum Angle 4D15M 4D14M42S
Outer Cone Distance 5.080 Inch (129.0 mm) 5.190 Inch (131.8 mm)
Face Width 1.428 Inch (36.27 mm) 1.459 Inch (37.06 mm)
Addendum .074 Inch (1.88 mm) .076 Inch (1.93 mm)
Dedendum .377 Inch (9.58 mm) .385 Inch (9.78 mm)
Distance Between Crossing 0.000 Inch 0.000 Inch
Point and Come Appex
Mounting Distance 2.000 Inch (50.80 mm) 2.041 Inch (51.84 mm)
CUTTER DATA
Cutter Diameter 9.000 Inch (228.6 mm) 9.195 Inch (233.5 nun)
Point Width .150 Inch (3.81 mm) .156 Inch (3.96 mm)
Outside Blade Angle 20DOM 20D2M60S
Inside Blade Angle 20DOM 19D59M35S
Outside Blade Radius .060 Inch (1.52 mm) .061 Inch (1.55 mm)
Inside Blade Radius .060 Inch (1.52 mm) .061 Inch (1.55 mm)
MACHINE SETTINGS
A-7
The electrodes were cut using EDM dielectric fluid as the gear
cutting coolant. The graphite used for the electrodes is porous in its
composition. Any coolant used during cutting of the teeth will be
absorbed by the graphite. If a standard cutting fluid is used, the oil
will not be compatible with the EDM process. Using dielectric fluid
eliminates this problem. Figure A-2 shows the electrode while the teeth
are being cut. Figure A-3 shows the electrode after machining.
A-8
FIGURE A-2. Machining of Electrodes
A-9
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REFERENCES
A-12
APPENDIX B
FORGING TRIALS
APPENDIX B
FORGING TRIALS
by National Machinery Company, Tiffin, Ohio, was used for the trials. The
press, shown in Figure B-i, was selected based upon the anticipated forging
load of about 2,500 tons and the space available for tooling. The forging
dies used in the trials are shown schematically in Figure 11. As can be
seen in this figure, metal flow into the flash is provided radially, in-
ward only.
bottom bolsters. In the bottom die holder, the tooling contains the
tooth form and represents the most critical portion of one tool assembly.
(It may be more advantageous to put the tooth form into the top die
was not possible in the present press because a top ejector was not
forgings were successfully forged and ejected from the die and no damage
to the tooling occurred. The process conditions for these forging trials
are as follows:
B-1
Gears
FIGURE B-I. Mechanical Press Used for Forging the
B-2
Billet Heating - Gas-Fired Furnace with Nitorgen
as a Protective Atmosphere
Billet Material - 8620 Steel
Twenty-one spiral bevel gears were forged. The fill of the gear
teeth was in general not as good as desired. Based upon the results of
these trials it was felt that there were two major reasons for not achiev-
ing the amount of fill desired, die design and scale. To improve the die
design, the die was to be vented to allow entrapped gases and lubricants
reduce oxidation.
2. Use induction heating to heat the billet, as
B-3
coil, allowing the neutral atmosphere to be trapped. An air cylinder
was mounted under the coil to lift the billet into the coil. The coil
was coupled to an induction generator which balances the voltage to
permit uniform heating. The coil was tested successfully at the vendor
prior to running the trials. The induction heating coil and material
handling device are shown in Figure B-2.
This frequency was used because the available generator had a high fre-
quency range; however, in real production, the frequency to be used
should be between 60 to 100 Hz, because the depth of current penetration
varies inversely as the square root of the frequency of the current.
Therefore, a through heating application, such as for forging, requires
generally lower frequencies than for surface hardening, brazing or
soldering.
B-4
t4
FIGURE B-2. The Induction Coil Set-Up Used in the Second and Third
Series of Forging Trials
B-5
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0B w
TABLE B-2. Evaluation of Forged Gears (Second Series)
* Total length of tooth top (B) was 1.915 inch (48.64 mm),
as seen in Figure B-3
B-7
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B-11I
part to be easily removed form the die. The dies were preheated with a
circular flame ring that fit into the die cavity as shown in Figure B-7.
This assured uniform heating of the die before forging. The flame ring
was placed around the die, while preforms were being heated, in order to
keep the die as warm as possible to minimize chilling and enhance filling.
(In production, it may be advantageous to have a built-in electric heating
or a die holder design that provides cooling and heating with a circulating
fluid.)
The teeth of the forgings were not filled 100% in the toe and
heel. The design of the radii on the preform did not allow enough material
in these areas to insure complete filling. A new preform was designed and
manufactured for use in the third series of trials for obtaining net forged
teeth (refer to the section on "Preform Design" of the main text of this
report).
The preforms were heated by induction, which heats from the out-
side into the center of the part. To obtain a uniform temperature through-
out the part, it was necessary to alternate heating and non-heating cycles.
The method followed was heat 2 minutes, soak in coil 30 seconds, heat 30
seconds, soak in coil 30 seconds, then remove from coil and forge. The
heating time of 2.5 minutes, given earlier, reflects this heating approach.
These trials were performed to forge the gears with net teeth.
The parts were heated in an induction heating coil with nitrogen serving as
an inert atmosphere. The billets were not precoated prior to heating since
billets without coating did not scale in Trials II. The coil and lifting
mechanism was the same as those used in Trials II. The preform temperature
was monitored during heating by means of a sight hole in the coil. The
billet was heated to 1,9300 F (1,0540 C), then allowed to have the heat
soak throughout the part until the outside of the ring-type preform was
1,7000 F (926.70 C). The part was reheated to 2,1000 F (1,148.90 C), allowed
to soak until it was down to 2,0000 F (1,0930 C), then forged. This heat/
soak procedure was necessary because the induction process heats the outside
of the part first with heat subsequently flowing towards the center. If this
B-12
FIGURE B-7. Heating of the Dies With a Circular Gas Flame
B-13
heating method is not followed, the center may be too cold to forge even
through the outside may be hot enough or overheated.
The parameters for Trials III were as follows:
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APPENDIX C
Nest Design
The forged part was first cleaned after forging to remove scale,
especially at the teeth. A nesting fixture was designed to hold the part
C-1
during the subsequent turning operations. The nest, shown in Figure C-i,
worked as a positive locating work-holding device. The forging was placed
in the nest, resting on the pitchline, as shown in Figure C-2. The part
was clamped on the back face near the outer diameter. The bore and back
face were machined after clamping, as seen in Figure C-3. From this machined
and qualified bore, the part is clamped from the turned back face through the
bore, as seen in Figure C-4. The outside clamps are removed, permitting the
remaining portion of the back face and the outer diameter to be turned,
Figure C-5. The forging is not removed from the nest during the entire
machining operation, thereby maintaining the positive location on the pitch-
line. This assures that all reference surfaces have the same orientation
and location with relation to the forged teeth.
After machining the bore and back face of the forged gears from
Trials II, they were put into a #28 Gleason gear cutter to finish machining
the teeth of the gear (by removing the machining allowance). The gear
cutting operation was very successful in producing the desired finish tooth
form from the forged parts. The cut teeth were to the designed tooth thick-
ness. The spiral angle, with both flanks of the entire tooth form, was
completely machined after a single gear cutting operation. These gear
cutting results verify that the CAD phase of this program was accurate in
predicting the machine settings used to produce the EDM electrode, made to
manufacture the die. A forged gear, with the teeth being finish machined,
is shown in Figure C-6.
After the gears forged in the second series of trials were
finish machined, a pinion was cut to match the tooth form on the gear.
This is necessary to compensate for any variations in the gear tooth form
as compared to the master set of gears. When the gear and pinion were
rolled on a gear tester, an acceptable contact pattern was produced. This
contact pattern is shown in Figure C-7.
C-2
FIGURE C-i. Nesting Fixture
C-3
41.
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C-9C
Finish Machining of Gears
from the Third Series of Trials
The gears with net forged teeth, from Trials III, were designed
without any machining stock on the teeth. The only machining required was
on the reference surfaces, namely, the bore and back face of the gear.
This machining procedure was the same as that used for machining the bore
and the back face of the gears forged in Trials II. After the net forged
gears were machined, it was again necessary to cut a pinion to match the
tooth form of the gear. The pinion was cut and rolled against the forged
gear teeth producing an acceptable contact patter. This contact pattern is
shown in Figure C-8.
FORGING INSPECTION
C-10
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CIRCULARCHORDAL
THICKNE SS ADDENDUM
PITCH
CIRCLE•- - ._
CHORDAL
THICKNESS
C-13
Figure C-1O. The addendum used from the gear
C-14
FIGURE C-1l. Gear Clamped on the Computer-Controlled Rotary Table
C-15
3-D probe head
cinematics
calibration
X5Y.
stored 4.
dj h's d5 coord.
X, &s
Y ts X5
Vs X.y,,z. / "'C ' alignment
C-16
- 0 C'J
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C-i 8
C-13 shows the plot of the profile of six teeth that were measured (teeth
Nos. 1, 6 and 13 are shown in Figure C-13a; teeth Nos. 20, 27 and 34 are
shown in Figure C-13b). The plots, shown in Figure C-13, show the relative
deviation of the forged tooth profile from a master gear tooth produced by
conventional cutting (using a Gleason generator). Note that the relative
error at the center of the profile is zero, i.e., the variations were
measured relative to the center of the coast and drive surfaces of the
master gear. The scale of the relative error is shown at the left side of
Figure C-13. Figure C-14 shows a 3-D representation of the profile measure-
ments. The plots of Figure C-13 show that the net forged gear tooth is an
excellent reproduction of the master gear tooth form with a maximum variation
of 0,003 inches (0.0762 mm). This minor difference can be easily compensated
for, during the cutting of the mating pinion.
Another form of output from the Zeiss machine is shown in Figure
C-15. This plot explains both the index variation and the pitch variation.
As shown in Figure C-11, the probe is placed between the first and 39th
tooth (forged gear has 39 teeth). It measures a point at the same height
and radius from the center to every tooth on the gear, The pitch variation
is measured to determine the differences in spacing between each two consecu-
tive teeth. The index variation is the cumulative variation of the differ-
ences in spacing between the first tooth and the consecutive teeth.
The results of the Zeiss machine measurements can also be presented
in tabular form as shown in Table C-1 and C-2. In Table C-1, X,Y, and Z rep-
resent the X,Y, and Z coordinates of points on the tooth surface measured
relative to the gear (workpiece) coordinate system. Figure C-16 illustrates
the machine coordinate system which is indicated with XM, YM and ZM, and
the workpiece coordinate system designated with XW, YW and ZW. The exact
position of the workpiece coordinate system is defined by probing a number
of surface points. In the example shown in Figure C-16, the surface normal
is measured with three points. Thus, the direction of axis ZW is also defined.
Two additional points define the direction of XW. Then another set of three
points define the origin of the workpiece coordinate system. Now the work-
piece is mathematically aligned, and all points to be measured will be
referred to the known workpiece coordinate system. So, in Table C-1, DX,
DY and DZ are the deviations of the measured point (on the forged gear)
C-19
5 22
C20
0 r
IN
x CUj
IN
. 40 0 0 0
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0 0 0 0 0 C
WL H
*u cu cu 0
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C-21
MEASURE RECURD ZEISS RAM 2b
UPERAIOR I DAlE
T.HMole I 412182
C I L I X I Y I Z I DX I DY I DZ I EN
ALIGNMENT MODE 0
TOOTH I FLANK I
1 1 3.64467 -0.42224 1.15400 -0.00094 0.00168 -0.00001 0.00173
1 2 3.bL528 -0.43149 1.19325 -0.00009 0.00159 0.00000 0.00166
1 3 3.b6638 -0.43948 1.23176 -0,00111 0.00197 0.00000 0.00205
1 4 3.70790 -0.44851 1.27114 -0.00087 0.00157 -0.00001 0.00164
1 5 3.72930 -0.45622 1.30999 -0.00113 0.00204 0.00000 0.00213
C I L I X I Y I Z I DX I DY I DZ I EN
C-22
100TH 1 FLANK 2
1 I 3.622158 -0.52922 1.10975 -0.0o105 0.00157 -0.00000 -0.00181
1 2 3.67875 -0.47754 1.16191 -0.00097 0.o0046 -0.00000 -0.00170
1 3 3.73204 -0.42743 1.21275 -0.00071 0.00121 0.00000 -0.00136
1 4 3.78,45 -0.37595 1.26356 -0.00072 0.00120 -0.00001 -0.00136
1 5 3.83818 -0.32300 1.31473 -0.00117 0.00185 0.00000 -0.00212
C IL.I X I Y I Z I DX I Dy I DZ I EN
C-23
INDEX MEASUREMENT RAM 2P
Battelle Gear
DRAWING NO I PART NO I ORDER NO ISUPPLIER/CUSTOMERI OPERATION
TACOM Cut Mstr. 1 #2-19 Fri 46795 Zeiss I Eaton Gr Dev Labl CoMparison
OPERATOR I DATE
T,H.Mole I 4/2/82
1 0100000 0.00000
2 0.00014 0.00014
3 -0.00023 -0.00009
4 -0.00001 -0.00011
5 -0.00032 -0,00043
6 -0,00014 -0.00058
7 0.00007 -0 00051
8 0,00037 -0.00014
9 -0.00039 -0.00052
10 0.00014 -0,00039
11 0.00053 0.00015
12 0.00051 0.00066
13 0.00009 0,00074
14 0.00026 0. 00100
15 0.00006 0,00107
16 0.00005 0.00111
17 -0,00003 0.00109
18 -0.00004 0,00105
19 0.00009 0,00114
20 -0.00028 0,00086
21 -0.00017 0.00069
22 0.00004 0.00073
23 -0,00038 0,00035
24 -0.00007 0,00028
25 -0,00003 0.00025
26 -0.00028 -0,00003
27 -0.00017 -0.00020
28 0,00030 0.00010
29 0.00026 0.00036
30 0,00023 0.00059
31 0,00051 0.00110
32 -0.00003 0.00107
33 0.00007 0.00114
34 -0.00028 0.00086
35 -0.00032 0.00054
36 -0.00023 0.00031
37 -0.00015 0. 00016
38 -0.00005 0.00011
39 -0.00015 -0,00004
1 0 .00004
C-24
z M
Xw
Yw
C-25
from the corresponding point on the nominal master gear manufactured by
cutting on a Gleason machine (generator). Now, if the unit vectors in the
directions of the workpiece (forged gear) axis are NX, NY and NZ, EN in Table
C-1 can be represented as:
EN = NX • DX + NY • DY + NZ • DZ
EN expresses the flank form deviation in the direction of the normal vector.
Table C-2 shows the numerical values of the pitch variations (fpl)
and the index variation (Fpkl). Both are discussed and represented graph-
ically in Figure C-15. The Zeiss measurements form a complete picture of
the teeth of the gear. The profile measurements (Figure C-13 and Table C-1)
show the tooth form variation, and the index measurements (Figure C-15 and
Table C-2) show the tooth spacing variation.
The results of the Zeiss measurements confirmed the accuracy of the
CAD/CAM system developed in this project. These results, for the three sets
of forging trials, are summarized in Tables C-3, C-4 and C-5.
C-26
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REPORT DISTRIBUTION
Commander
U.S. Army Tank Automotive Command
ATTN: DRSTA
Warren, Michigan 48090