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Section 3: Conventional Methods for Contact Pattern Development |
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2) Understanding Contact Pattern and Gear Displacement 3) Conventional Methods for Contact Pattern Development 4) A New Method for Contact Pattern Development 5) Developing the Contact Pattern Through Computer Modeling: 6) Duplication of Operating Conditions with Universal Load Testers A Case Study of the PW6000 Project 8) Troubleshooting and Failure Analysis 9) Contact Arrow's Design Engineering Team
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The size and position of the contact pattern has always been a primary design consideration for gears. And for many years, achieving a good contact pattern was performed through the same methods that the vast majority of gear producers still use today. The conventional method of achieving an ideal contact pattern is performed in this way. First an engineer will make an educated guess at the gear tooth geometry required to provide a correct contact pattern. Next the part is fabricated and the gear teeth are machined to an undeveloped summary. When the gear and
its mating pinion are finished, they are run together in a tester. More
often than not, the contact pattern will not be correct in this first
attempt But how will the gear perform under load in a gearbox and what will the contact pattern look like then? This leads to more steps in the trial and error process. First the gears are mounted in the gearbox and run under light load to determine the contact pattern movement. Then the gears are visually inspected to check the contact pattern - which is indicated by a light wear pattern on the mating tooth surfaces. If the pattern is not correct, which is commonly the case, the gear tooth grinder has to be setup again with new machine settings and another pinion is ground. This cycle continues until a suitable contact pattern is developed when run under full load. For a new gear design, this process can take several months to complete. And while this is a time consuming and costly process, it was just the way it had to be done – or it was until recently with the availability of new computer-based technologies for gear development. |
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Section 3: Conventional Methods for Contact Pattern Development |
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This requires going back and changing the settings on the gear tooth grinder,
then producing a new pinion. The parts are checked again. This trial and
error process can continue through many cycles until the best educated
guess for contact pattern location is achieved.