• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.19 no.10
• /
• pp.36-43
• /
• 2020

A marine turning gear is the main auxiliary machine that enables the disassembly of and maintenance on the main engines. In this study, a marine turning gear based on a helical planetary reducer was developed through analysis of a marine turning gear based on a spur planetary reducer. Nonlinear numerical analysis was performed to determine the ideal contact ratio between the sun gear and the idle gear. Based on this, the surface durability, tooth bending strength, and contact ratio were calculated. In addition, the helix direction was selected to utilize the existing bearings. Gears were manufactured based on the helical gear design values, and the turning gear was evaluated using the FTA standards of MAN Co. Ltd. As a result, a lifetime of 3,000 to 5,000 hours was verified, the maximum torque measured was 105kNm, and the efficiency was measured to be 87.4%.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.21 no.2
• /
• pp.64-72
• /
• 2022

Gear designers need to select the proper tolerances for deviations in both the center distance and parallelism of axes because these deviations cause high stresses and lead to fatigue breakage of the teeth. In this study, a three-dimensional finite element analysis model was developed for a helical gear used in metro vehicles, and a bending stress analysis method for gear pairs was established according to the contact position change. Using this model, the effect of shaft misalignment due to the center distance and shaft parallelism deviations on the bending stress of the gear was analyzed. As a result, the magnitude of the bending stress changed nearly linearly with the change in the center distance deviation. The tooth contact of the helical gear is biased toward the end of the tooth width when the parallelism deviations of the shaft occur, and the tooth root bending stress increases.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1999.03b
• /
• pp.111-114
• /
• 1999

The twisting and extrusion process of the product with involute helical fin from the round billet is developed by the upper bound analysis. The twisting of extruded product is caused by the twisted die surface connecting the die entrance section and the die exit section linearly. In the analysis, the internal shear surface is defined as the curved twisted plane from the taisting of die surface and the shear work is calculated by the consumption of shear energy The increase rate of angular velocity is determined by the minimization of plastic work. The results of the analysis show that the angular velocity of the extruded product increases with the die twisting angle, the reduction of area, and decreases with the die length, the friction condition.

• Transactions of Materials Processing
• /
• v.10 no.4
• /
• pp.302-310
• /
• 2001

The twisting and extrusion process of the product with involute helical fin from the round billet is developed by the upper bound analysis. The twisting of extruded product is caused by the twisted inclined die surface connecting the die enterance section and the die exit section linearly. In the analysis, the internal shear surface is defined as the curved twisted plane from the twisting of die surface and the shear work is calculated by the consumption of shear energy. The increase rate of angular velocity is determined by the minimization of plastic work. The angular velocity of die exit can be controlled by the land length and the length of inclined die. The alular velocity assums to be increased linearly by the axial distance from the die enterance to the die exit. The results of the analysis show that the angular velocity of the extruded product increases with the die twisting angle, the reduction of area, and decreases with the die length, the friction constant.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2005.10a
• /
• pp.158-161
• /
• 2005

In this paper, the precision electric discharge machining technology, the powder electric discharge machining technology, is applied to making a cold forging die for making the helical type of clutch gear. Various working conditions are investigated with emphasis on reduction of the electrode wear and enhancement of the surface roughness. Through the research work, the key technology of making the helical gear forging dies is achieved.

• Transactions of Materials Processing
• /
• v.8 no.4
• /
• pp.384-392
• /
• 1999

In metal forming, there are problems with recurrent geometric characteristics without explicitly prescibed boundary conditions. In such problems, so-called recurrent boundary conditions must be introduced. In this paper, as a practical application of the proposed method, the precision cold forging of a helical gear has been simulated by a three-dimensional rigid-plastic finite element method and compared with the experiment. The application of recurrent boundary conditions to helical gear forging analysis is proved to be effective and valid. the elastic stress analysis of the die for helical gear forging has been calculated by using the nodal force at the final stage obtained from the rigid-plastic finite element analysis. In order to obtain more precise gear products, the elastic analysis of the die after release of punch and the elastic spring-back analysis of product after ejection have been performed, and the final dimension of the computational product has been in good agreement with that of the experimental product.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1999.03b
• /
• pp.237-240
• /
• 1999

The elastic stress analysis of the die for helical gear forging has been calculated by using the nodal force at the final stage obtained from the rigid-plastic finite element analysis. In order to obtain more precise gear products. the elastic analysis of the die after release of punch and the elastic spring-back analysis of product after ejection have been performed and the final dimension of the computational product has been in good agreement with that of the experimental product.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1994.03a
• /
• pp.37-46
• /
• 1994

In metal forming, there ar problems with recurrent geometric characteristics and without explicitly prescribed boundary conditions. In such problems, so-called recurrent boundary conditions must be introduced. The present study deals with nonsteady-state three-dimensional finite element analysis for extrusion of a trocoidal helical gear through a curved die. The boundary-directed remeshing scheme based on the modular remeshing technique is developed to reduce the errors arising in fitting old and new mesh systems. The computed extrusion pressure in reaching the near steady-state loading stage is compared with the results of the experiment and the steady-state analysis. The three-dimensional deformed pattern involving warping at the extruded end due to torsional deformation mode is demonstrated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.05a
• /
• pp.139-142
• /
• 2009

As important mechanical elements, gears have been used widely in power transferring systems such as automobile transmission and there have been several researches trying to make gear parts with cold or warm forging in order to reduce cost and time required to gear manufacturing process. Although forging processes of spur and bevel gears have been developed as practical level owing to active previous researches in Korea, the manufacturing of helical gear has been still depended on traditional gear cutting processes such as hobbing, deburring and shaving. In order to manufacture helical gears with cold forging process, a research project supported by government has been conducted by Daegu university, KIMS and TAK and this paper deals with effects of back pressure forming technique to cold forging of helical gear as a fundamental research.

• Transactions of Materials Processing
• /
• v.14 no.5 s.77
• /
• pp.444-451
• /
• 2005

A new extrusion process of the circular section product with helical fins could be developed by rotating extrusion die. The twisting of extruded product is caused by the twisted conical die surface connecting the die entrance section and the die exit section linearly. But, until now, because the process has used fixed extrusion die, it needs high pressure in order to twist billet and form fin shape on the surface of billet. So, during extruding billet, in order not to twist billet, the extrusion die is needed to rotate itself instead of twisting of billet. It is known that it is possible to reduce extrusion load of product with helical fins by analysis and experiments using rotating die. And it is known that, through the extrusion load analysis by $DEFORM^{TM}-3D$ software, optimal rotational velocity of rotating die can be obtained according to reduction ratio of area and twisted angle of die. And experiments and analysis using rotating extrusion die show that the twisted angle of product can be controlled by twisted angle of extrusion helical die and the rotational velocity of extrusion helical die.