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The Advanced Manufacturing Technologies of Metal Gears
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The Advanced Manufacturing Technologies of Metal Gears

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (15 December 2024) | Viewed by 14371

Special Issue Editors

Dr. Yuansheng Zhou

E-Mail Website
Guest Editor
State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha 410083, China
Interests: gear design and manufacturing; CAD/CAM/CAE/CAO; intelligent manufacturing; digital twins
Dr. Wen Shao

E-Mail Website
Guest Editor
State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha 410083, China
Interests: gear anti-fatigue design and manufacturing; surface strengthening and modification techniques; manufacturing science; advanced manufacturing technologies; machining mechaism analysis; mechanical characterization engineering; finite element medelling; molecular dynamic modelling; advanced materials
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Chaosheng Song

E-Mail Website
Guest Editor
State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400030, China
Interests: gear geometry design; gear dynamics; beveloid gear; spiral bevel and hypoid gears
Prof. Dr. Shuai Mo

E-Mail Website
Guest Editor
School of Mechanical Engineering, Guangxi University, Nanning 530004, China
Interests: gear transmission; face gear; planetary gear transmission; gear dynamics; nonlinear dynamics; load sharing of split gear transmission

Special Issue Information

Dear Colleagues,

Metal gears can serve a long life even in the case with high speed and heavy load, and their applications are directly affected by the manufacturing technologies. With the increasing requirements for high performance, the manufacturing technologies are also put forward to achieve the high efficiency, accuracy, and strong mechanical properties. This Special Issue focuses on the recent advanced manufacturing technologies in the field of metal gears. The purpose is to improve the quality and competitive advantage of metal gears and meet the high requirements of gear products by attracting many experts and scholars to develop the advanced technologies in the same field.

Potential topics for this Special Issue on metal gears include, but are not limited to, the following aspects:

  • Efficient or accurate manufacturing processes;
  • Hybrid manufacturing processes;
  • Surface integrity of tooth;
  • Anti-fatigue manufacturing technologies;
  • Intelligent manufacturing;
  • The collaboration between manufacturing and design, analysis, assembly, or others.

Dr. Yuansheng Zhou
Dr. Wen Shao
Prof. Dr. Chaosheng Song
Prof. Dr. Shuai Mo
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • metal gears
  • advanced manufacturing technology
  • surface integrity
  • anti-fatigue manufacturing
  • intelligent manufacturing

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Published Papers (6 papers)

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Research

16 pages, 24977 KiB  
Article
Towards Understanding Subsurface Characteristics in Burn Process of Gear Profile Grinding
by Jun Wen, Jinyuan Tang, Wen Shao, Weihua Zhou and Weiwei Huang
Materials 2023, 16(6), 2493; https://doi.org/10.3390/ma16062493 - 21 Mar 2023
Cited by 8 | Viewed by 2209
Abstract
In gear profile grinding, the grinding burn will greatly influence the anti-fatigue performance of gears. However, the influence of microstructure change caused by grinding burn on gear surface integrity is still unclear. In this paper, full-factor experiments of gear profile grinding are conducted [...] Read more.
In gear profile grinding, the grinding burn will greatly influence the anti-fatigue performance of gears. However, the influence of microstructure change caused by grinding burn on gear surface integrity is still unclear. In this paper, full-factor experiments of gear profile grinding are conducted and the grinding temperature is measured during the experiments. Furthermore, the tooth surface integrity including microstructure, residual stress, microhardness, and surface morphology is characterized. The relationship between grinding parameters, grinding burns and subsurface layer properties is analyzed by systematical test results. Radial grinding depths of more than 20 μm matched with wheel speeds below 30 m/s will result in severe grinding burns. The effect of grinding burns on the grain state mainly results in the breakdown of high strength martensite and the formation of inhomogeneous secondary tempered sorbite. The recovery and recrystallization of the microstructure of the tooth subsurface layer after grinding burns is the root cause of the substantial reduction in compressive residual stress and nano-hardness. The occurrence of grinding burns is mainly due to the unreasonable matching of process parameters rather than being influenced by a single grinding parameter alone. The risk of burn can be significantly reduced at greater wheel speeds and lower radial grinding depth. This study presents an insight into the mechanism of the effect of gear profile grinding burns on the surface integrity of the tooth flank. Full article
(This article belongs to the Special Issue The Advanced Manufacturing Technologies of Metal Gears)
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19 pages, 7995 KiB  
Article
Precise Shrink Fitting Design of the High Strength Gear Mold for the Precision Forging of Noncircular Spur Bevel Gears
by Wuhao Zhuang, Lin Hua, Xinghui Han, Wei Feng, Yanhui Wang and Mingzhang Chen
Materials 2023, 16(4), 1556; https://doi.org/10.3390/ma16041556 - 13 Feb 2023
Cited by 1 | Viewed by 2516
Abstract
Shrink fitting of forging mold (SFFM) is an effective method for improving mold strength, extending the mold’s service life and reducing the manufacturing cost of forging mold. However, due to the asymmetric geometry and complex stress distribution, the precise design of SFFM for [...] Read more.
Shrink fitting of forging mold (SFFM) is an effective method for improving mold strength, extending the mold’s service life and reducing the manufacturing cost of forging mold. However, due to the asymmetric geometry and complex stress distribution, the precise design of SFFM for the precision forging of noncircular bevel gears is very difficult. In this paper, a new precise design method of SFFM for the precision forging of noncircular bevel gears is proposed, which mainly includes the following five parts. First, a new design method for the mold parting surface—the curved surface parting method—is proposed to design the forging mold of noncircular spur bevel gears. Then, new dimension design methods for the gear mold and shrink rings based on the uniform shrinkage force are proposed. Third, a new design method for the inhomogeneous interference value between shrink rings and the gear mold is developed to provide a precise, uniform shrinkage force. After that, a strength correction method for the shrink-fitted gear mold is proposed to ensure the gear mold and shrink rings have sufficient strength both in the assembly process of the shrink-fitted gear mold and precision in the forging process of noncircular spur bevel gears. Ultimately, finite element simulations and verification experiments are performed to verify the proposed precise design method of SFFM for the precision forging of noncircular bevel gears. The precise design method of SFFM proposed in this paper is not only applicable to the precise design of the high-strength gear mold for noncircular bevel gears, but can also provide a valid reference for the precise design of the high-strength mold for other complicated asymmetric parts. Full article
(This article belongs to the Special Issue The Advanced Manufacturing Technologies of Metal Gears)
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21 pages, 11894 KiB  
Article
Simulation and Experimental Verification of Die Quenching Deformation of Aviation Carburized Face Gear
by Huaming Liu, Jiuyue Zhao, Jinyuan Tang, Wen Shao and Beier Sun
Materials 2023, 16(2), 690; https://doi.org/10.3390/ma16020690 - 10 Jan 2023
Cited by 16 | Viewed by 2596
Abstract
The tooth width and length of face gear limit control the strength of face gear, and heat treatments are often used to improve the hardness and strength of face gear. However, heat treatments will often cause additional deformations, which will affect the dimensional [...] Read more.
The tooth width and length of face gear limit control the strength of face gear, and heat treatments are often used to improve the hardness and strength of face gear. However, heat treatments will often cause additional deformations, which will affect the dimensional accuracy of the face gear. In this paper, to effectively control the deformation and ensure the accuracy of the face gear, the finite element method was used to establish the calculation model of the face gear die quenching method, and thus, the influence of die on the gear quenching deformation was analyzed. Next, the accuracy of the calculation model was verified by the pressure quenching experiment. The results demonstrated that the inconsistent phase transformation between the surface and the center of the face gear was the key factor affecting the deformation due to the influence of the carbon content. Compared with die-less quenching, the inner hole-die can effectively limit the radial shrinkage deformation of the face gear. With the increase of the upper-die pressure, the axial and radial deformations of the face gear gradually became stable. In the actual production, the load of dies should be reasonably selected based on the gear accuracy requirements. Full article
(This article belongs to the Special Issue The Advanced Manufacturing Technologies of Metal Gears)
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14 pages, 5015 KiB  
Article
An Innovative Flexible-Honing Method with Dampers for Long-Life, Mass-Machining of Face Gears
by Xiaomeng Chu, Zhiji Zhou, Hong Zeng, Yanzhong Wang and Yizhan Huang
Materials 2022, 15(23), 8573; https://doi.org/10.3390/ma15238573 - 1 Dec 2022
Viewed by 1751
Abstract
To further exert the technical advantages of face gears, high-end equipment puts forward the need for the long-life mass-machining of face gears. However, the commonly used technique of hard honing is more sensitive to installation errors and impact loads, and soft honing has [...] Read more.
To further exert the technical advantages of face gears, high-end equipment puts forward the need for the long-life mass-machining of face gears. However, the commonly used technique of hard honing is more sensitive to installation errors and impact loads, and soft honing has insufficient removal ability to the margin, so the quality of the gear’s life is difficult to guarantee. To solve this contradiction, this paper introduces a damper to honing and proposes a flexible honing method for face gears. First, to reveal the flexible honing mechanism, the tooth-surface model of face-gear honing is derived, and the mathematical model for face-gear flexible honing is established. Second, to clarify the influence of flexible honing parameters on the quality of the tooth surface, a roughness model of the honing surface is established, and the influence of flexible honing parameters on roughness is analyzed. Third, by analyzing the influence of roughness under the action of honing parameters on the stress of the tooth surface, the parameters for flexible honing are determined. Finally, the effectiveness of the method is verified by flexible honing machining and testing. Full article
(This article belongs to the Special Issue The Advanced Manufacturing Technologies of Metal Gears)
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27 pages, 6863 KiB  
Article
An Analytical and Experimental Study on Cutting Characteristics and Transient Cutting Force Modeling in Feed Directional Ultrasonic Vibration-Assisted Cutting of High Strength Alloys
by Xuelin Chen, Jinyuan Tang, Wen Shao, Bo Hu and Jinxiang Ye
Materials 2022, 15(20), 7388; https://doi.org/10.3390/ma15207388 - 21 Oct 2022
Cited by 7 | Viewed by 2233
Abstract
Ultrasonic vibration-assisted cutting (UVC) is progressively being used in machining as it can significantly promote the fabrication process. However, the ultrasonic vibration affecting the cutting process is still controversial. The full-transient cutting process is proposed in this study to analyze the affecting mechanism [...] Read more.
Ultrasonic vibration-assisted cutting (UVC) is progressively being used in machining as it can significantly promote the fabrication process. However, the ultrasonic vibration affecting the cutting process is still controversial. The full-transient cutting process is proposed in this study to analyze the affecting mechanism induced by ultrasonic vibration in the cutting process. This novel model is the first developed based on the fact that ultrasonic vibration would change mechanical behaviors and the cutting process. For example, the reduction of shear flowing stress in the primary shear zone and alteration of the shear angle in the UVC process. Then, considering those coupled effects, a novel model is proposed to determine the average and transient cutting forces. Here, insight and understanding into the physical phenomenon in UVC are provided. The effectiveness of the proposed model is verified by comparison with experimental results and analytical models available in the literature, with cutting parameters varying from macro to micro-scale. The results show that the ultrasonic vibration affects the cutting process in a complicated way, which is determined by transient characteristics, acoustic softening, thermal softening, plowing, and friction. Those effects on cutting performances in the UVC process under various cutting scenarios are investigated and discussed systematically. The average deviation of cutting forces between experiments and values predicted by the proposed model for Ti6Al4V, AISI 1045, and Al6063 is about 7%, 10.2%, and 11%, respectively. The deviation decreases with the increase of cutting speed in the machining of Ti6Al4V, which is different from the machining of other materials. This is contributed by the varied effect of ultrasonic vibration on the cutting process. Full article
(This article belongs to the Special Issue The Advanced Manufacturing Technologies of Metal Gears)
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16 pages, 23393 KiB  
Article
Strength Matching Method of Face Gear Pair Considering Service Space Limitation to Improve Strength Performance
by Xiaomeng Chu, Hong Zeng, Yanzhong Wang and Yizhan Huang
Materials 2022, 15(20), 7081; https://doi.org/10.3390/ma15207081 - 12 Oct 2022
Viewed by 1569
Abstract
To further improve maneuverability and passability, new heavy-duty vehicles place higher demands on the service space and strength performance of transmission systems. The new surface gear transmission stands out for its unique technical advantages, but how to reduce the volume as much as [...] Read more.
To further improve maneuverability and passability, new heavy-duty vehicles place higher demands on the service space and strength performance of transmission systems. The new surface gear transmission stands out for its unique technical advantages, but how to reduce the volume as much as possible under the premise of meeting the strength performance remains difficult to research. In the past, the method of improving the strength performance of the face gear pair has usually been by increasing the parameters and optimizing the tooth profile. These methods are not suitable for use considering space constraints and guaranteeing center-to-center distances. To overcome the contradiction between small volume and large load, this work proposes a strength matching method to improve the face gear pair’s strength performance in limited service space. First, according to the meshing principle of the face gear pair, the displacement coefficient is considered in the configuration process of the face gear pair, and the mathematical model of the face gear pair is established. Second, to ensure the effective contact area of the face gear pair, a mathematical model of the reverse contact trace avoiding the undercutting and pointing area is established. The proposed method is validated by electrolytic machining and transmission performance tests. This research solves application problems, such as the strength mismatch of the face gear transmission system, and lays the foundation for the engineering application of face gear. Full article
(This article belongs to the Special Issue The Advanced Manufacturing Technologies of Metal Gears)
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