• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2002.04a
• /
• pp.85-91
• /
• 2002

Of all the many types of machine elements which exist today, gears are among the most commonly used. Many researches have been done to manufacture helical gears by cold forging and extrusion. Although cold forging and extrusion were applied to some bevel, spur, and helical gears, problems in connection with reducing forming load and tool life still make it difficult for the related methods to be commercialized. In this study, focusing on reducing load in forming helical gears, extrusion of helical gears by a two-step process is proposed. The process is composed of an extrusion step of spur gears used as preform and a torsion step of the preform to make helical gears. Upper-bound analysis for the two-step process is performed and compared with results of experiments. The newly proposed method can be used as an advanced forming technique to remarkably reduce the forming load and replace the conventional forming process of helical gears.

• International Journal of Advanced Culture Technology
• /
• v.6 no.3
• /
• pp.163-172
• /
• 2018

The power train of hydro-mechanical continuously variable transmission(HMCVT) for the middle class forklift makes use of an hydro-static unit, hydraulic multi-wet disc brake & clutches and complex helical & planetary gears. The complex helical & planetary gears are a very important part of the transmission because of strength problems. The helical & planetary gears belong to the very important part of the HMCVT's power train where strength problems are the main concerns including the gear bending stress, the gear compressive stress and scoring failures. The present study, calculates specifications of the complex helical & planetary gear train and analyzes the gear bending and compressive stresses of the gears. It is necessary to analyze gear bending and compressive stresses confidently for an optimal design of the complex helical & planetary gears in respect of cost and reliability. This paper not only analyzes actual gear bending and compressive stresses of complex helical & planetary gears using Lewes & Hertz equation, but also verifies the calculated specifications of the complex helical & planetary gears by evaluating the results with the data of allowable bending and compressive stress from the Stress - No. of cycles curves of gears. In addition, this paper explains actual gear scoring and evaluates the possibility of scoring failure of complex helical & planetary gear train of hydro-mechanical continuously variable transmission for the forklift.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2002.10a
• /
• pp.824-828
• /
• 2002

Of all the many types of machine elements which exist today, gears are among the most commonly used. Many researches have been done to manufacture helical gears by cold forging and extrusion. Although cold forging and extrusion were applied to some bevel, spur, and helical gears, problems in connection with reducing forming load and tool life still make it difficult for the related methods to be commercialized. In this study, focusing on reducing load in forming helical gears, extrusion of helical gears by a two-step process is proposed. The process is composed of an extrusion step of spur gears used as preform and a torsion step of the preform to make helical gears. Upper-bound analysis for the two-step process is performed and compared with results of experiments. The newly proposed method can be used as an advanced forming technique to remarkably reduce the forming load and replace the conventional forming process of helical gears.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
• /
• 2007.11a
• /
• pp.1042-1048
• /
• 2007

This work analytically investigated the radiated noise of a helical gear-housing system due to the excitation of helical gears. The helical gears were modeled as a 12-degree of freedom mass-spring-damper system; the shaft was modeled as a rod, a beam, and a torsional shaft; and the gear housing was modeled as a clamped circular plate with viscous damping. The modeling of this system used transfer matrices for helical gears, shafts, and bearings. Damping for both the bearings and the plate were obtained by modal testing. For the evaluation of noise, sound pressure from the plate due to the force and the moment in both radial and tangential directions was analytically derived by the Rayleigh integral. The analytical derivation and parameters from the experiment were applied to an analysis of noise for the two sets of helical gears with differing gear ratios. The analysis showed that the moment excitation in both helical gears contributed more to the noise of the plate than axial force excitation.

• Journal of Drive and Control
• /
• v.13 no.4
• /
• pp.45-51
• /
• 2016

The power train of a hydro-mechanical, continuously variable transmission for forklifts makes use of hydro-static units, hydraulic multi-wet disc brakes & clutches, and complex helical & planetary gears. The complex helical & planetary gears are very important parts of the transmission because of a strength problem. In the present study, we calculated the specifications of the complex helical & planetary gear train, and analyzed the gear bending and compressive stresses of the gears. It is necessary to analyze the gear bending and compressive stresses thoroughly for optimal design of the complex helical & planetary gears with respect to cost and reliability. In this paper, we analyze the actual gear bending and compressive stresses of complex helical & planetary gears using the Lewes & Hertz equation, and we also verify the calculated specifications of the complex helical & planetary gears by evaluating the results of the data of allowable bending and compressive stress using the Stress vrs Number of Cycles curves of gears.

• Transactions of the Korean Society for Noise and Vibration Engineering
• /
• v.20 no.7
• /
• pp.677-684
• /
• 2010

Backlashes of gears provide gears for good lubrication and for removal of the interference between teeth by the wear and manufacturing errors. The backlash is the strong nonlinear factor to gears. This study deals with nonlinear modeling of helical gears with backlash. Excitation of helical gears comes from torque variation, the tooth surface error, and the periodical change of mesh stiffness. To study the effect of torque fluctuation, equation of motion for the single degree of freedom torsional model of helical gears with the periodical change of mesh stiffness and the backlash was derived. The Newmark beta method and the Newton-Raphson method were used to obtain the nonlinear behaviors of mesh forces of helical gears. All excitation frequencies initially caused the tooth separation and single-sided impacts of the gear pair and eventually led to the normal tooth contact. However, some special excitation frequencies caused the single-sided impacts in the entire time as well as the initial time. Damping increase reduced the duration of single-sided impacts, and the backlash increase caused those in the entire time domain.

• Transactions of the Korean Society for Noise and Vibration Engineering
• /
• v.22 no.4
• /
• pp.358-364
• /
• 2012

This work dealt with dynamic characteristics of spur gear and helical gear system to understand the gear vibration and noise. To find out dynamic characteristics in the gear system, a finite element model and an analytic model for the gear system were used. Using the models, the natural frequency and mode-shape characteristics of spur gears and helical gears were calculated. Two models show that natural frequencies of helical gears were lower than those of spur gears. Mode-shape characteristics of gear pairs by analytical model and some issues of finite element modeling were also discussed. Impact test was used to validate the finite element model.

• Transactions of Materials Processing
• /
• v.20 no.7
• /
• pp.485-490
• /
• 2011

The application of helical gears in crucial parts of automotive transmissions has been steadily increasing due to their higher power transfer performance compared to spur gears. However, the traditional gear manufacturing methods such as hobbing and deburring require large cycle times with expensive production lines so that there have been intensive efforts trying to manufacture gears via forging processes. Although forging processes for spur and bevel type gears have been developed on the practical level, the manufacturing of helical gears is still dependent on the traditional cutting process. Therefore, this paper seeks to develop a cold forward extrusion process for the helical gear with the pitch diameter of 43.5mm and a helix angle of $18.4^{\circ}$. A forward extrusion process was used due to the relatively small diameter of the target geometry. The material deforming behavior influenced by the die geometry was examined by using CAE analysis. Finally, it was found that the helical gear manufactured by the developed extrusion process satisfied the dimensional accuracy and mechanical characteristics for automotive transmissions.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
• /
• 2006.05a
• /
• pp.774-781
• /
• 2006

This paper presents a study on the analytical prediction of vibration transmission from helical gears to the bearing. The proposed method is based on the application of the three dimensional helical gear behaviors and complete description of shaft by the spectral method. Helical gear system used in this paper consists of the driving element, helical gears, shafts, bearings, couplings and load element. In order to describe all translation and rotation motion of helical gears twelve degree of freedom equations of motion by the transmission error excitation are derived. Using these equations, transfer matrix for the helical gear is derived. For the detail behavior of shaft motion, the $12{\times}12$ transfer matrix for the shaft is derived. Transfer matrix for the bearing, coupling, driving element, and load is also derived. Application of the boundary conditions in the assembled transfer matrix produces the forces and displacements in each element of the helical gear system. The effect of the proposed method is shown by numerical example.

• Proceedings of the KSME Conference
• /
• 2001.06c
• /
• pp.470-475
• /
• 2001

The elevator gear box with the helical gears needs to be developed instead of the one with the worm gears to improve the efficiency. In order to develop the gear box, the analytical tool to predict the helical gear noise is necessary to meet customer's noise requirement. Gear noise is related to the loaded transmission error. Therefore, the simulation program for the loaded transmission error analysis of the helical gears is developed in this study. Using the developed program, the effects of tooth modification such as tip relief and the extent of tip relief are investigated. Finally, the procedures to determine the tip relief and the extent of tip relief are proposed.