2011-03-23 12:14:33 40187

(Gearing) 1 ()

(Gear) (Introduction to Gear) (Gear) (Torque)

1 1. (Type of Gears) 1.1 (Spur Gears) (Spur gear) 2 (Parallelshaft Gear)

2 (Spur Gear) (Pinion Gears) (Module, m) (, Ratio) (Transmission Component)* * (Trust) (No Axial Force) * * 1.2 (Helical Gears) 3

3 (Helical Gears)* (Load) (Helical Gear) (Load) (Spur Gear) * (Overlap) * (Trust) 1.3 (Herringbone Gears or Double Helical Gears) (Trust) 4 (Load)

4 (Double Helical Gears or Herringbone Gears)1.4 (Rack Gears) (Gear) (Spur Gear) (Rack) (Gear)

5 (Rack Gears)* * Plot * (Robot)* (Steering)1.5 (Internal Gear, Ring Gear) 6 (Ring) (Pinion) 6 (Pinion Gear)

6 Internal Gear1.6 (Bevel Gear) (Straight Bevel Gear) (Spiral Bevel Gear) (Shaft) (Intersect) 90

7 (Straight Bevel Gear)

8 (Spiral Bevel Gear) 1.6.1 (Straight Bevel Gear) * * 1:5 (Differential Gear)

9 1.6.2 (Spiral Bevel Gear) (Curve 8A) ( ) * (Ratio) * * * 1.6.3 (Hypoid Gears) 8B (Normally Conical)

10 (Sliding) (Straight Gear) (Worm Gear)

11 1.7 (Miter Gear)Miter Gear (Ratio) 1:1 90 12

12 Miter Gear

13 (Screw Gears or Spiral Gears)1.8 (Screw Gears or Spiral Gears) 90 13 * * (Sliding Contact) * (Driving Gear for Automobile) 1.9 (Worm Gears) (Worm) (Shank) (Worm Wheel) (Helical Gear) 14 (Worm Shaft) (Worm Wheel Shaft) 90 (Sliding)

14 (Worm Gears) (Shank) (Worm Wheel) (Center Distance) Center Distance 1 (Worm Gear Ratio)

* (Center Distance)*

15

16 1 1

[1] Introduction to Gears: First Edition KOHARA GEAR INDUSTRY, Kawaguchi-shi, Japan, November.1, 2006[2] John J. Coy Gearing, National Aeronautics and Space Administration (NASA), NASA Lewis Research Center, Ohio, 1985[3] MARKS Standard Handbook for Mechanical Engineer, 11th Edition, Mc GrawHill, New York, 2007[4] Gear technical reference KOHARA GEAR INDUSTRY, Kawaguchi-shi, Japan,

(Gearing) 1 () ()

2. (Gear Terminology) (Addendum) (Dedendum) (Depth) (Clearance) (Pressure Angle) ( 17 )

17

18 Circular Pitch 2.1 (Tooth Proportions) 2 (Metric) (Module) (DP=Diameter Pitch) * (Module, M) (Module, m) , Circular Pitch, Cp = m ... (3) CP Circular Pitch , mm 3.14

19 * DP (Diametral Pitch, DP) (DP Gear) Diametral Pitch 1 DP , /, N PD ,

20 DP = 48 48 1 2 48 48/2 = 24/ 24 2 24/2 = 12/* (Module, m) () CP Circular Diameter Pitch, mm CP = m ... (6) 2 64 / CP = [25.4 (1)]/64 = 1.24682 mm (m) 2.54/1.24682 = 3.9688 mm 2

2.2 (Module, M) Diametral Pitch, DP* Circular Pitch, p ( 15 ) (Pitch Circle) p , mm m z * * Base Diameter * Backlash * (Center Distance) * (Circular Thickness) * (Outside Diameter) * (Pressure Angle) (Tangent) 21 (Spur Gear) 21 Pressure Angle Tangent Tangent (Pressure Angle) (Pressure Angle) 14.5, 20 25 ANSI 20 (Load) (Pressure Angle) 25 (Pressure Angle) 14.5

21 (Pressure Angle)

22 Single Stage Gear Train* (Gear Ratio, Mesh Ratio, mG) (Single Stage Gear Train) (Mashing) mG (Mesh Ratio) NG, z2 (Teeth on Gear or Following), NP, z1 (Teeth on Pinion or Driving), n1 , rpm n2 , rpm

(Idle Gear) 23 10

23 Single Stage with Idle Gear Train

24 (Single Stage Gear Pair) (Two Stage Gear Train) 25 25 2 2 3 11

25 Single Stage with Idle Gear Train 25 1 10 (z1 = 10) 2 24 (z2 = 24) 3 12 (z3 = 12) 3 2 4 30 (z4 = 30) 2 1 2 2 3 4 3 25

3. (Gears Material) (Bending Allowable) (Hertz Stress, Hertz (Contact) Stress?) (Wear Resistance) (Impact Strength) (Corrosion Resistance) (Manufacturing Cost) Off Road 3.1 (Plastic) (Load) (Polymer) (Nylon) (Polyimide) (Load) (MC Nylon) 4 4

4 121 Co (Yield Strength) 81 MPa 26 27

26 StressStrain

27

28 (Water Absorbsion) 4 1.5% 28 100%, 50% 3.2 (Nonferrous Metal) (Aluminum) (Sliding) (Titanium) (Slide) 3.3 (Copper Alloy) (Bronze) (Worm Gear) (Yield Strength) 138414 MPa 5 5

3.4 (Cast Iron) (Sliding) (Impact Load or Shock Load) (Malleable Iron) (Ductile Iron) Heat Treatments (Bending Strength) 34 172 MPa 345 739 MPa (Sliding) 3.5 (Sintered Powder Metals) (Powder) (Accuracy) 3.6 (Hardness Steel) (Load) (High Accuracy) (Load)

29 (Speed) (Lubrication) Heat Treatment (Bending Stress) 138 MPa (Hertz Stress, Hertz (Contact) Stress) 586 MPa (Load) (Surface Heat Treatment) (Carburizing) (Nitriding) (Medium Carbon) (Bending Stress) 345414Mpa (Hertz Stress, Hertz (Contact) Stress) 1,140 MPa (Sliding) 6

[1] Introduction to Gears: First Edition KOHARA GEAR INDUSTRY, Kawaguchi-shi, Japan, November.1, 2006 [2] John J. Coy Gearing, National Aeronautics and Space Administration (NASA), NASA Lewis Research Center, Ohio, 1985 [3] MARKS Standard Handbook for Mechanical Engineer, 11th Edition, Mc GrawHill, New York, 2007 [4] Gear technical reference KOHARA GEAR INDUSTRY, Kawaguchi-shi, Japan,

(Gearing) 2 ()

(Gear) (Gear) * (Ratio) * (Torque) (Force) * 1.

1 (Gear) * (Vibration Measurment Tool) * (Thermal Photographic Tool) * (Oil Analysis Medthod) *

2 (Rolling) (Sliding) 2. (Different between Failure and Wear) 30 30 (Failure) 3. 5862 HRC * (Load) * * (Impact Load) * * * * 4. (American Gear Manufacturers Association, AGMA) 5 * (Wearing) * (Surface Fatigue) * (Plastic Flow) * (Breakage) * (Associated Gear Failures) (Gear Box) 5. 5.1 (Wearing) 5.1.1 (Polishing) (Sliding) (Rolling) (Load) * * Oil Cooller

3 (Polishing Type Wear) 5.1.2 (Moderate Wear)

4 (Moderate Wear) (Moderate Wear) * ISO VG220 ISO VG320 Cooling * * (Gear Box) Spray * * Off Line (Load) 5.1.3 (Extreme Wear) (Moderate Wear) (Pitting) (Load) (Vibratory load)

5 (Extream Wear) 5.1.4 (Abrasive Wear) (Gear Box) 6

6 (Abrasive Wear) (Air Breather) (Gear Box) 5.1.5 (Corrosive Wear) 7 (Extream Pressure Additive) (R&O, Anti Rust and Oxidation Additive) * * (Gear Box) Air Breather

7 (Corrosive Wear) 5.1.6 (Scoring )

8 (Scoring Wear) (Wearing) (Missalignment) 8 (Load) (Oil Cooller) 60 C 5.2 (Surface Fatigue Failure) (Repeat Load) 5.2.1 (Pitting) (Cycle) (Pitting) 0.4~0.8 (Load)

9

10 5.2.2 (Destructive Pitting) 10 5.2.3 (Micropitting) 11 12 0.0025 (2.5?) (Load) (Load)

11 (Micropitting)

12 (Micropitting Magnified) 5.2.4 (Spalling) 14

13 Spalling

14 5.2.5 (Case Crushing) 14 (Load) Carburized Nitrided Induction Hardened 15

15 5.3 (Plastic Flow) (Rolling) (Sliding) (Load) 3 5.3.1 , (Peening) (Load) (Stress) (Rolling) (Sliding) 5.3.2 (Rippling) (Load) * (Load) * (Load) * * (Extream Pressure Additive)

16 (Ripping)

17 (Ridging) 5.3.3 (Ridging) (Slide) (Worm Gear) Pinoin Gear Drive (Sliding) 5.4 (Breakage Failure) (Load) (Impact Load) 5.4.1 (Bending Fatigue Breakage) 18

18

19 5.4.1 (Overload Breakage) (Load) * (Bearing) 20 * * * (Torque-limiting Couplings), Shear Pin

20 5.4.2 (Random Fracture) Filler 5.5 (Associated Gear Failures) (Crack) 5.5.1 Quenching cracks Quenching Cooling Quenching

21 Quenching Cracks

22 Grinding Cracks 5.5.2 Grinding Cracks 22 0.08~1.3 5.5.3 (Rim and Web Failures) (23) (Load) ()

23 Rim and Web Failures

24 Electric Current Damage 5.5.4 Electric Current Damage 24 (Ground) [1] Failure Analysis for Gearing Gary DeLange., http://www.lubecontrol.com.au[2] http://www.tribology.co.uk

(Gearing) 3 ()

1. (Gear Box, Close System)

1 (Gearbox) * * 60 C *

2 Air Breather Filter * Air Breather (Air Breather) Air Breather * 1 * 2. (Open Gear Box) (Load) (Open Gear Box) * *

3 (Open Gearbox) (Load) * (Viscosity) * (Base Oil Type) 3 (Mineral Oil) (Semi Synthetic Oil) (Fully Synthetic Oil) * (Gear Lubricant Type and Additive Selection) 1. (Viscosity of Lubricant Oil) (Load)

4 ISO (International Organization for Standardization) ISO VG( Viscosity Grade) 40 C ISO VG46 40 40 C (40cSt @ 40 C) ISO VG680 680 40 C (680cSt @ 40 C) AGMA (American Gear Manufacturers Association) 6 ISO VG AGMA 1 1 AGMA Grade ISO VG

1.1 (Load) (Pitch Line Velocity) ANSI (American National Standards Institute) AGMA (American Gear Manufacturers Association) Standard ANSI/AGMA 9005-E02 (Load) (Viscosity Index) 2 (Spur Gear) (Helical Gear) (Beveled Gear) 2 1 (Pitch-line Velocity, PLV) (Load) 2 1 PLV = rP (1) 2

PLV , m/s rP,m ( 5) (=2Ns) Ns, /

5 1.2 (Base Oil) (Base Oil) . (Mineral Oil) (VI) . (Synthetic Oil) 1.3 (Viscoscity Grade) (Rust and Oxidation Inhibited, R&O) (Anti Scuff) (EP or Extream Pressure Additive) (Anti Wear)

6 1.3.1 (Detergent) (Alkaline) (Sulphuric) (Nitric) (Neutral Detergents) (Anti-corrosion) (Anti-wear) (Alkaline) 1.3.2 (Rust and Oxidation Inhibited, R&O) 100 ?C ZDTP (Zinc Dialkyldi Thio Phosphate) (R&O) o (Chemical Stability) o (Demulsibility) o (Corrosion Prevention and Foam Suppression) (Load) (Hydrodynamic) Rolling and Sliding Elastohyrodynamic Lubrication (EHD or EHL) 8 R&O Boundary Lubrication

7 Hydrodynamic

8 Elastohyrodynamic

9 Boundary 1.3.3 (Antiscuff, Anti ware or Extreme Pressure) Gear Lubricants (Zinc and Phosphorus-based) (Extreme Pressure, EP) EP (Extreme Pressure) (Load) Extream Pressure, EP R&O EP (Load) Boundary EP Additive o (Load) o o (Load) (Shock Load) (Sulfur) (Phosphorous) Zinc Dialkyl Dithio Phosphate (ZDDP) Molybdenum-disulfide, MoS2 (Moly)

10 ZDDP

11 MoS2 1.3.4 (Anti Foam Additive) 1.3.5 (Dispersants) (Filter) 1.3.6 (Pour Point Depressants) (Mineral Oil) Paraffin Waxes Paraffin Waxes (Polymethacrylates) 1.3.7 (Polymer Thickeners) 1.3.8 (Corrosion Protection) 3

[1] Jarrod Potteiger, "What You Need to Know When Selecting Gear Oils". Machinery Lubrication Magazine. September 2006 [2] http://www.tribology.co.uk[3] ANSI/AGMA 9005-E02 Industrial Gear Lubrication