AGMA-02FTM1-2002.pdf
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1、02FTM1 The Effect of Chemically Accelerated Vibratory Finishing on Gear Metrology by: J. Arvin, Arrow Gear Company, A. Manesh, Power Transfer Systems Manufacturing, M. Michaud, G. Sroka, and L. Winkelmann, REM Chemicals, Inc. TECHNICAL PAPER American Gear Manufacturers Association Copyright American
2、 Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 11:10:39 MDTNo reproduction or networking permitted without license from IHS -,-,- The Effect of Chemically Accelerated Vibratory Finishing on Gear
3、Metrology Joseph Arvin, Arrow Gear Company, Ali Manesh, Power Transfer Systems Manufacturing, Mark Michaud, Gary Sroka, Lane Winkelmann, REM Chemicals, Inc. Thestatementsandopinionscontainedhereinarethoseoftheauthorandshouldnotbeconstruedasanofficialactionor opinion of the American Gear Manufacturer
4、s Association. Abstract Chemically accelerated vibratory finishing is a commercially proven process that is capable of isotropically superfinishingmetalstoanRa1.0in.Surprisingbenefitswerefoundwhenthistechnologywasappliedtogears.Such gearshavereducedfriction,wearandnoise. Contactfatigue(pitting)andbe
5、ndingfatiguearealsoreducedoreliminated both in laboratory testing and field trials. Since the metal removal rate using this process is dependent on the amount of surface rubbing by the media, gear engineers are often concerned with its impact on gear geometry. Inthispaper,aerospaceAGMAQ13spiralbevel
6、gearswerestudied.Itwas shownthat theamount ofmetal removedto Isotropicsuperfinish(ISF)thesurfaceisbothnegligibleandcontrollable.Allofthegearsweresuperfinisheduniformly and were determined to be within tolerance. Inadditiontoprofilometryandmetrologydata,mediaselectionandmetalremovalmonitoringprocedur
7、esaredescribed that ensure uniform surface finishing, controllability, and preservation of gear metrology. Copyright 2002 American Gear Manufacturers Association 1500 King Street, Suite 201 Alexandria, Virginia, 22314 October, 2002 ISBN: 1- -55589- -801- -7 Copyright American Gear Manufacturers Asso
8、ciation Provided by IHS under license with AGMA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 11:10:39 MDTNo reproduction or networking permitted without license from IHS -,-,- 1 The Effect of Chemically Accelerated Vibratory Finishing on Gear Metrology Joseph Arvin
9、*, Ali Manesh+, Mark Michaud#, Gary Sroka#, Lane Winkelmann# * Arrow Gear Company, Downers Grove, IL + Power Transfer Systems Manufacturing, Chicago, IL # REM Chemicals, Inc., Brenham, TX Introduction Chemically accelerated vibratory finishing enhances the performance of components that are subjecte
10、d to metal-to-metal contact or bending fatigue. When the resultant surface has an Ra of approximately 3.0 in. or less and a non-directional surface pattern, it will be referred to here as an Isotropic Superfinish (ISF). Such surfaces are unique in their remarkable ability to reduce friction1, 2, 3,
11、4, wear1, 2, 3, 4, noise5, as well as contact3, 6, 7, and dynamic fatigue8 when compared to similar surface finishes produced by other techniques. There has been increasing interest in applying this process to gears since industry is being driven to produce higher cycle life gears at increased power
12、 densities. ISF is produced in vibratory finishing bowls or tubs. A proprietary active chemistry is used in the vibratory machine in conjunction with high-density, non-abrasive ceramic media9. When introduced into the machine, this active chemistry produces a stable, soft conversion coating on the s
13、urface of the metal part(s) being processed. The rubbing motion across the part(s) developed by the machine and media effectively wipes the conversion coating off the “peaks” of the parts surfaces, but leaves the “valleys” untouched. (No finishing occurs where media is unable to contact or rub.) The
14、 conversion coating is continually re-formed and rubbed off during this stage producing a surface smoothing mechanism. This process is continued in the vibratory machine until the surfaces of the part(s) are free of asperities. At this point, the active chemistry is rinsed from the machine with a ne
15、utral soap. The conversion coating is rubbed off the part(s) one final time to produce the ISF surface. In this final step, commonly referred to as burnishing, no metal is removed. The ISF process removes more metal from the region of a part where higher media contact occurs. Therefore, more stock w
16、ill be removed from the addendum than from the root fillet of a gear. Naturally, gear engineers and designers question whether the ISF process will negatively affect gear geometry especially for AGMA Q11 and higher. This paper presents before and after (ISF processed) metrology data that is represen
17、tative of the 11 AGMA Q13 spiral bevel gears and pinions examined during this study. It was concluded that the ISF processed gears and pinions maintained their Q13 rating. Description of Gears Figure 1 shows a schematic of the gearset used in this study, which were manufactured by Arrow Gear Company
18、. The alloy was SAE 9310 case hardened to 57-62 HRC. The initial surface roughnesses were: Pinions (in.) Gears (in.) Ra 7 to 11 5 to 13 Rz 42 to 81 33 to 87 Ra: Arithmetical Mean Roughness (DIN 4768) Rz: Mean Peak-to-Valley Height (DIN 4768/1) Figure 2 shows photographs of a gearset and the masking
19、that protected the threaded holes and bearing areas during ISF processing. Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 11:10:39 MDTNo reproduction or networking permitted wit
20、hout license from IHS -,-,- 2 Figure 1. Schematic of gearset used in this study. Figure 2. Photographs of a gearset showing protective masking of threaded holes and bearing areas. The ISF Process Smoothing Principle Before proceeding with the rest of the discussion, it is important to discuss the ba
21、sic principles of the ISF process in greater detail. The process utilizes conventional vibratory finishing equipment and high density, non- abrasive finishing media9 to produce isotropic surface finishes which can have an Ra as low as 1.0 in. Refer to Figure 3. At the start of the ISF process (Step
22、1), the original metal surface reacts a first time with the active chemistry, forming the first conversion coating (Step 2). The vibratory machine and non-abrasive media produce an effective rubbing motion on the surface of the metal part(s) (Step 3). This exposes the peaks of the metal surfaces to
23、a second reaction (Step 4), re- forming the complete conversion coating. The process of conversion coating re- formation and removal (Step 5) is continued through many successive cycles. This process is continued until the metal parts are smoothed to the required surface finish quality. Once the req
24、uired surface finish quality is achieved, the active chemistry from the smoothing stage of the ISF process is drained away, and a neutral, burnishing soap is introduced into the vibratory machine. The burnish removes all remaining conversion coating (Step 6) from the surface of the part(s), producin
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