WO2020201987A1 - Procédé de fabrication de grande couronne d'ensemble différentiel et appareil associé - Google Patents

Procédé de fabrication de grande couronne d'ensemble différentiel et appareil associé Download PDF

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Publication number
WO2020201987A1
WO2020201987A1 PCT/IB2020/053010 IB2020053010W WO2020201987A1 WO 2020201987 A1 WO2020201987 A1 WO 2020201987A1 IB 2020053010 W IB2020053010 W IB 2020053010W WO 2020201987 A1 WO2020201987 A1 WO 2020201987A1
Authority
WO
WIPO (PCT)
Prior art keywords
fixture
crown gear
differential housing
grinding
gear
Prior art date
Application number
PCT/IB2020/053010
Other languages
English (en)
Inventor
Babasaheb Neelkanth Kalyani
Prashant Prabhakar NALADKAR
Chandrashekhar Dnyaneshwar WANGATE
Hari Pandurang KADAM
Anilkumar Shantilal SUTHAR
Original Assignee
Bharat Forge Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bharat Forge Limited filed Critical Bharat Forge Limited
Publication of WO2020201987A1 publication Critical patent/WO2020201987A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23F—MAKING GEARS OR TOOTHED RACKS
    • B23F5/00—Making straight gear teeth involving moving a tool relatively to a workpiece with a rolling-off or an enveloping motion with respect to the gear teeth to be made
    • B23F5/20—Making straight gear teeth involving moving a tool relatively to a workpiece with a rolling-off or an enveloping motion with respect to the gear teeth to be made by milling
    • B23F5/22—Making straight gear teeth involving moving a tool relatively to a workpiece with a rolling-off or an enveloping motion with respect to the gear teeth to be made by milling the tool being a hob for making spur gears
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23F—MAKING GEARS OR TOOTHED RACKS
    • B23F19/00—Finishing gear teeth by other tools than those used for manufacturing gear teeth
    • B23F19/10—Chamfering the end edges of gear teeth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23F—MAKING GEARS OR TOOTHED RACKS
    • B23F23/00—Accessories or equipment combined with or arranged in, or specially designed to form part of, gear-cutting machines
    • B23F23/12—Other devices, e.g. tool holders; Checking devices for controlling workpieces in machines for manufacturing gear teeth
    • B23F23/1218—Checking devices for controlling workpieces in machines for manufacturing gear teeth

Definitions

  • the present invention relates to machining of a crown gear used in a differential assembly. Particularly it relates to grinding of the crown gear teeth profile and face in the assembled condition with differential housing/casing.
  • a differential is used in an automobile to drive a pair of wheels such that it allows the wheels to rotate at same or different speeds. At different speeds, the differential allows the outer wheels of an automobile to rotate faster than the inner wheels during a turn.
  • a crown gear is an important part of the differential assembly which transmits the torque from the engine of an automobile to its wheels through the differential. It is important to manufacture the teeth profile of crown gear with the accuracy of ISO 1328-1 1995 Grade 5. The lead and the run out of the crown gear along the length, OD and the profile twist needs to be maintained as per the accuracy of the grade.
  • the crown gear teeth profile and the differential housing are machined individually as separate components within the prescribed tolerances and then assembled together by bolting. This conventional process of machining the components individually and assembling them after machining, leads to the crown gear profile being out of tolerances when inspected in assembled condition with differential housing.
  • Present invention relates to the machining or grinding of the crown gear profile in an assembled condition with the differential housing.
  • the invented process elaborates the machining or grinding of crown gear teeth profile in assembled condition with the differential housing.
  • a special enclosed type of fixture is manufactured for grinding of crown gear teeth profile to avoid the grinding dust or burrs to enter differential housing sub-assembly.
  • Figure 1 shows a sub-assembly of typical crown gear and differential housing Figure 2 shows conventional manufacturing process of crown gear
  • FIG. 3 shows the Fixture- 1 clamped with sub-assembly of crown gear and differential housing in accordance with one implementation of the present invention
  • FIG 3a shows the sectional and isometric views of Fixture- 1
  • Figure 4 shows the Fixture-2 clamped with sub-assembly of crown gear and differential housing in accordance with one implementation of the present invention
  • Figure 4a shows the isometric view of Fixture-2 in accordance with one implementation of the present invention
  • FIG. 5 shows steps involved in manufacturing process of crown gear in accordance with one implementation of the present invention
  • Figure 6 shows sub-steps involved in crown gear face and teeth grinding in accordance with one implementation of the present invention
  • the present invention is focused on eliminating the stated drawbacks/limitations of conventional manufacturing processes. This is achieved by providing the grinding method for crown gear teeth profde (3) and bottom face (16) in the assembled condition with differential housing (1) with help of Fixture-1 (10) and Fixture-2 (11).
  • the key inventive feature of the present invention is the sequence of manufacturing method and special fixtures (10, 11) used in order to grind the teeth (3) and bottom face (16) of crown gear (2) in assembled condition with differential housing (1) within the ISO 1328-1 1995 Grade 5 tolerances.
  • the said crown gear (2) comprises array of gear teeth profile (3), Gear Flank (4), OD (5), ID (6), Resting face (7), bore (8), Crown gear face (9), Crown gear top face (13), Crown gear bottom face (16);
  • the said differential housing (1) comprises Differential housing OD (12), Top side OD (14) of differential housing (1), Bottom side OD (15) of differential housing (1), and the ID (18) of the Differential Housing (1).
  • FIG. 2 shows the conventional manufacturing method to produce any typical crown gear (2) of differential. The major steps involved in this are as follows.
  • the crown gear (2) is assembled with the differential housing (1) before performing the face (16) and teeth profde (3) grinding on the crown gear (2).
  • the invented manufacturing process is as show in Figure 5. The steps of process are given below.
  • Gear Hobbing Next, gear hobbing is performed on the drilled disc to produce a hobbed disc. In this operation, rough teeth profde is generated on crown gear using a gear hobbing machine to achieve good accuracy in rough condition.
  • Heat treatment preferably case carburizing, is done on the chamfered disc to produce a heat treated disc. Heat treatment is carried out to achieve the required case depth and hardness on the crown gear flanks (4), crown gear OD (5), crown gear ID (6).
  • Hard Turning Hard turning the bore and face of the heat treated disc is done to produce crown gear (2). The squareness of the crown gear bore (8) and resting face (7) is maintained within 0.020 mm in hard turning process.
  • Cleaning Next, a cleaning machine is used to ensure the washing of the crown gear and the differential housing in such way that no machined burrs are present.
  • Assembly In the next step, the crown gear (2) and the differential housing (1) are sub-assembled by press fitting and bolting with required torque.
  • Bottom face grinding Next, grinding of the bottom face (16) of the crown gear (2) is carried out, while in assembled condition with the differential housing (1), using Fixture-1 (10).
  • Washing-1 Next, Washing of the sub-assembly is done to remove grinding dust or burrs produced during the bottom face grinding operation.
  • Teeth grinding is performed on the Crown gear (2), while in assembled condition with differential housing (1), with the help of Fixture-2 (11).
  • the critical gear teeth parameters like Profile Slope Deviation ( ⁇ 5 microns) and Helix Slope Deviation ( ⁇ 8 microns) are maintained in this grinding operation.
  • Washing-2 Next, Washing of the sub-assembly is done to remove grinding dust or burrs produced during the teeth grinding operation.
  • Fixture- 1 (10) is used to grind the bottom face (16) of the crown gear (2). As shown in the Figure 3, the crown gear (2) and differential housing (1), in assembled condition, are mounted on the Fixture- 1 (10).
  • Fixture-1 (10) consists of hydraulically actuated mandrel (17) which clamps the differential housing ID (18) with the mandrel OD (17) in order to accommodate the sub-assembly of crown gear (2) and differential housing (1) onto the Fixture- 1 (10).
  • the mandrel (17) is loaded on the machine between centres by using driving carrier at step OD (19).
  • Runout of the bottom face (16) of the crown gear (2) is a very important parameter in order to achieve the crown gear teeth parameters during the subsequent crown gear teeth profde grinding operation.
  • Runout of the bottom face (16) of the crown gear (2) is maintained below 0.01 mm during this side face grinding operation using Fixture-1 (10).
  • Perpendicularity or squareness of the bottom face (16) of the crown gear (2) with respect to the differential housing OD (12) is also maintained within 0.01 mm during this operation.
  • FIG 3a shows the sectional and isometric view of special Fixture- 1 (10).
  • This Fixture-1 (10) is used during the grinding of crown gear bottom face (16).
  • Special features of this fixture are as follows:
  • Fixture- 1 Hydraulic actuation of Fixture- 1 will ensure the concentricity between differential housing ID (18) and bottom side OD of differential housing (15) after the grinding of this OD.
  • the said Fixture-1 (10) used for the grinding of crown gear side face (16) comprises mandrel (17), Sleeve (21) and Step OD (19).
  • the mandrel (17) has cylindrical shape while the inner side of sleeve (21) is cylindrical while the outer side can be cylindrical or conical or polygonal.
  • the diameter of Step OD (19) and mandrel (17) of Fixture- 1 (10) is same.
  • the sleeve (21) and mandrel are joined to each other by any joining means preferably by bolting.
  • the mandrel (17) is in contact with differential housing ID (18).
  • the bottom side OD (15) of differential housing is located in the inner diameter of sleeve (21).
  • Fixture- 1 locates the mandrel (17) into the differential housing ID (18) thereby maintaining the concentricity between differential housing ID (18) and bottom side OD of differential housing (15).
  • the Step OD (19) is used to load the Fixture-1 (10) on the grinding machine.
  • Fixture-2 (11) is used to grind the crown gear teeth profde (3).
  • the Fixture-2 (11) along with sub-assembly of crown gear (2) and differential housing (1) loaded on it is as shown in Figure 4.
  • This Fixture-2 (11) is having two parts i.e. Fixture-2 enclosure (11A) and locator (11E).
  • This Fixture-2 (11) is mounted on the grinding machine by bolting it to the base through bolting holes (11D).
  • the perpendicularity or squareness between Face of Fixture-2 (11B) supporting crown gear and Fixture-2 ID (11C) is maintained within 0.01 mm.
  • Tailstock centre (20) of grinding machine is located on the Fixture-2 enclosure (11A) of Fixture-2 (11).
  • Runout of this tailstock centre (20) is checked and verified within 0.005 mm.
  • the crown gear (2) and differential housing (1) sub-assembly as shown figure 1 is mounted on this Fixture-2 (11) after caring out the grinding operation of crown gear bottom face (16).
  • Bottom side OD of differential housing (15) is clamped into the Fixture-2 ID (11C) by means of hydraulic clamping.
  • Runout of Crown gear top face (13) and Top side OD of differential housing (14) is verified in order to ensure the proper clamping of this sub-assembly.
  • the Fixture-2 enclosure (11E) is provided on this sub-assembly to avoid the dust or burr to enter into this sub-assembly during the crown gear teeth profile (3) grinding.
  • FIG 4a shows the sectional and isometric view of Fixture-2 (11).
  • This Fixture-2 (11) is used during the crown gear teeth profile (3) grinding.
  • Some special features of this fixture are as follows,
  • Fixture-2 (11) is provided with Fixture-2 enclosure (11A) to avoid the entering of dust or burr during gear teeth profile grinding.
  • the said Fixture-2 (11) used for the grinding of crown gear teeth profile (3) comprises Fixture-2 enclosure (11A), Face of Fixture-2 (11B) supporting crown gear, Fixture-2 ID (11C), bolting holes for mounting Fixture-2 (1 ID) and Locator (11 E).
  • Fixture-2 enclosure 11A
  • Face of Fixture-2 11B
  • Fixture-2 ID 11C
  • Boling holes for mounting Fixture-2 (1 ID)
  • Locator 11 E
  • the details of the sub-steps performed on a crown gear (2) in an assembled condition with differential housing (1) during grinding of crown gear bottom face (16) and teeth profile (3) are explained in line with Figures 3, 4, 5 and 6.
  • the sequential sub-steps for grinding crown gear face and teeth profile are explained as follows:
  • Fixture- 1 (10) is used to perform grinding on the bottom face (16) of the crown gear (2) in assembled condition with differential housing (1). This Fixture- 1 (10) is clamped on base body of gear grinding machine with the help of Step OD (19) of Fixture-1 (10).
  • Sub-assembly washing is performed to ensure its cleanliness.
  • Locator (11E) of crown gear teeth grinding Fixture-2 (11), as shown in Figure 4 is loaded on the base body of gear grinding machine as vertically as possible.
  • Locator (11E) of Fixture-2 (11) as shown in Figure 4 is clamped as vertically as possible on the base of gear grinding machine with the help of bolts.
  • the run out of the Fixture-2 ID (11C) and Fixture-2 face (11B) is kept within 0.010 mm and checked by using dial indicator.
  • the enclosure (11A) is placed as shown in Fig.4 on the top face (13) of the crown gear to avoid entering of grinding dust or burr into differential housing sub-assembly, which essentially comprises the crown gear (2) bolted on the differential housing (1).
  • xii. CNC program is developed for grinding crown gear teeth profile (3). CNC program input is provided to gear grinding machine. The grinding of crown gear teeth profile (3) is performed in assembled condition with differential housing (1). xiii. Final Inspection is done on the gear tester machine. It was found that all crown gear profile geometry are within the tolerances as per the quality standard ISO 1328-1 1995 Grade 5.
  • the invention has a number of embodiments.
  • the invention discloses a method for manufacturing crown gear of differential assembly and grinding its teeth profile (3). The method has the following steps:
  • said grinding of said bottom face (16) of said crown gear (2) in assembled condition with differential housing (1) is carried out using Fixture- 1 (10) of said step i, further wherein said Fixture- 1 (10) comprises a mandrel (17), sleeve (21) and step OD (19), wherein said mandrel (17) is cylindrical in shape and the inner side of said sleeve (21) is cylindrical while the outer side of said sleeve (21) is either cylindrical or conical or polygonal; also wherein the diameter of said step OD (19) and that of said mandrel (17) of Fixture-1 (10) is equal; and wherein said sleeve (21) and mandrel (17) are joined to each other by any joining means such as bolting; wherein said mandrel (17) is in contact with differential housing ID (18) of said differential housing (1); wherein the bottom side OD (15) of said differential housing (1) is located in
  • grinding of teeth profile (3) of said crown gear (2) in assembled condition with differential housing (1) is carried out using said Fixture-2 (11) of said step k, wherein said Fixture-2 (11) comprises an enclosure (11A) and a locator (11E); wherein the said Fixture-2 (11) is mounted on said grinding machine by bolting it to the base of said grinding machine through bolting holes (1 ID); further wherein tailstock centre (20) of said grinding machine is located on said Fixture-2 enclosure (11A) of Fixture-2 (11); and wherein said crown gear (2) and differential housing (1) sub-assembly is mounted on said Fixture-2 (11) after carrying out the grinding operation of the bottom face (16) of the crown gear (2); and wherein said bottom side OD (15) of said differential housing (1) is clamped into the Fixture-2 ID (11C) by means of hydraulic clamping.
  • said Fixture-2 (11) comprises an enclosure (11A) and a locator (11E); wherein the said Fixture-2 (11) is mounted on said grinding machine by bolting it to the base of said grinding machine through bolt
  • said step i has the following sequential sub-steps: Clamping the Fixture- 1 (10) on base body of gear grinding machine with the help of Step OD (19) of Fixture-1 (10);
  • said step k has the following sequential sub-steps:
  • the alignment between Fixture-2 ID (11C) of said Fixture-2 (11) and bottom OD (15) of said differential housing (1) is achieved using hydraulic means.
  • the squareness of Fixture-2 ID (11C) and Face of Fixture-2 supporting crown gear (11B) is maintained by hydraulic actuation of Fixture-2 (11).
  • said Fixture-2 (11) is provided with Fixture-2 enclosure (11A) to avoid the entry of dust or burrs during gear teeth profile grinding.
  • an apparatus to carry out the method comprises Fixture- 1 and Fixture-2.
  • the said Fixture- 1 (10) for carrying out grinding of the Bottom face (16) of said crown gear (2) in assembled condition with differential housing (1) further comprises a mandrel (17), sleeve (21) and step OD (19), wherein said mandrel (17) is in cylindrical shape and the inner side of said sleeve (21) is cylindrical while the outer side of said sleeve (21) is either cylindrical or conical or polygonal; also wherein the diameter of said step OD (19) and that of said mandrel (17) of Fixture- 1 (10) is equal; and wherein said sleeve (21) and mandrel (17) are joined to each other by any joining means such as bolting; wherein said mandrel (17) is in contact with differential housing ID (18) of said differential housing (1); wherein the bottom side OD (15) of said differential housing (1) is located in the inner diameter of sleeve (21); and
  • the said Fixture-2 (11) for carrying out grinding of teeth profile (3) of said crown gear (2) in assembled condition with differential housing (1) characterised in that said Fixture-2 further comprises an enclosure (11A) and a locator (11E); wherein the said Fixture-2 is mounted on said grinding machine by bolting it to the base of said grinding machine through bolting holes (11D); further wherein tailstock centre (20) of said grinding machine is located on said enclosure (11A); and wherein said crown gear (2) and differential housing (1) sub-assembly is mounted on said Fixture-2 (11) after carrying out the grinding operation of the bottom face
  • the process of grinding of crown gear teeth profile (3) and face (16) in assembled condition with the differential housing (1) has several advantages in terms of quality of the crown gear (2).
  • the parameters like crown lead variation, crown gear run out along length and OD and crown gear profile twist are achieved within the tolerances as per the quality standard ISO 1328-1 1995 Grade 5.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Retarders (AREA)

Abstract

La présente invention concerne un procédé de fabrication de grande couronne. Le profil des dents et la face de la grande couronne sont dotés, à l'état assemblé, d'un carter de différentiel. Le procédé comprend les étapes consistant à tourner, percer un trou à diamètre de perçage sur le disque tourné, tailler à la fraise-mère sur le disque percé, chanfreiner le disque taillé à la fraise-mère, traiter thermiquement et tourner le disque chanfreiné pour produire une grande couronne et la nettoyer, puis assembler la grande couronne avec le carter de différentiel et réaliser un meulage de face inférieure et un meulage des dents à l'état assemblé à l'aide d'un appareil spécialement conçu, l'appareil comprenant des éléments de fixation 1 et des éléments de fixation 2 qui facilitent les actionnements hydrauliques des composants nécessaires ainsi que la concentricité et la perpendicularité/rectitude des composants nécessaires pendant le processus de meulage.
PCT/IB2020/053010 2019-03-30 2020-03-30 Procédé de fabrication de grande couronne d'ensemble différentiel et appareil associé WO2020201987A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201921012937 2019-03-30
IN201921012937 2019-03-30

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WO2020201987A1 true WO2020201987A1 (fr) 2020-10-08

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3487585A (en) * 1965-02-04 1970-01-06 Reishauer Ag Hobbing type gear grinder
US8175742B1 (en) * 2003-04-08 2012-05-08 Arvin Joseph L Apparatus and method for machining workpieces

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3487585A (en) * 1965-02-04 1970-01-06 Reishauer Ag Hobbing type gear grinder
US8175742B1 (en) * 2003-04-08 2012-05-08 Arvin Joseph L Apparatus and method for machining workpieces

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