Research On The Theory & Techniques Of Double-Flank Gear Rolling Test With Many Degrees Of Freedom

Gears are un-replaceable in modern industry although it was applied long long ago. In 2007, the annual production value in gear industry is RMB 420 billion in the world and it is up to RMB 89 billion in China, while 2/3 of the total amount is vehicle gear. In American vehicle gear industry, the produced gears are inspected to 100%. Gear measurement technology in measuring room is well-developed, but how to inspect the gears fast in workshop is a problem. Research in this field in China is mostly not present.The measurement principle of double-flank gear rolling test was applied in the existing fast gear inspection in workshop, because of its simple measurement principle, high efficiency, less requirements concerning the environment, and easy manufacturing of the master gear. Radial composite deviations can be assessed through the traditional double-flank gear rolling tester, but it is hard to obtain axial deviations (helix, taper, etc.), which is very important to gear life-span, vibration and noise.Based on double-flank gear rolling test, to obtain axial deviations, this thesis researched on the theory & techniques of double-flank gear rolling test with many degrees of freedom (DFMD). The main work is as follows.(1) Studied the implementation way of DFMD measurement principle, where axial deviations were obtained in gimbal mechanism. Established the model & differential eguation of the measuring system, analyzed the dynamic characteristics and the influence to the inspection results from the inherented frequency, measuring speed and damp.(2) Defined new axial deviations: radial composite helical slope deviation and radial composite helical taper deviation. The assessment methods were given. Analyzed the relationship between the gear manufacturing factors and the new axial deviations to validate the necessity to establish the new deviations.(3) Developed the in-line gear measuring machine based on DFMD measurement principle. Introduced the structure of the measuring system, the mechanical base unit, the measuring and auto-control hardware, and the data processing software for test & control.(4) Calibration method was given. The special workpiece, special slope gear and special taper gear was used in calibration, while the master gear and special master gear was used in measurement. This thesis designed the special gears. (5) Analyzed the system measurement uncertainty. The uncertainty in helical slope deviation measurement was calculated according to the errors from mechanical system, gauge system and data processing system. The following experiments were carried out in the measuring system: check the accuracy of the system, static test, dynamic characteristics test, function test and repeatability test.