Gear Cutting Cost Optimization by Hob Tool Communization through Simulation

Abstract

the transmission system is one of the main parts that determines the behaviour, power and fuel economy of a vehicle. Transmission performance is usually related to gear efficiency, gear noise and gear shift comfort during gear change. Apart from the above performance parameters COST plays an important role for downsizing the cost of vehicles in these competitive markets. Cost reduction processes are running in every module of vehicle such in engine no of cylinder downsizing from 4 to 3 cylinders. Weight reduction in overall powertrain housings & structural components. But this is not enough to achieve overall vehicle target cost reduction so there is a need of exploring other cost reduction parameters such as alternate material, alternate suppliers, alternate manufacturing processes or use of common tools to manufacture the parts with different configurations & sizes. Considering tool communization as an opportunity a virtual study was done based on the engineering calculations & use of gear generation principles. Taking professional software as a tool problem of hobbing simulation on involute gear was studied and virtual hobbing simulation of hobbing on the whole gear was completed by using macros of AutoCAD, key factors of gears and the cutting tool have been identified and their effect on gear simulation are shown by calculation process. Through this simulation process a single hob tool profile was simulated on different gears to see the effect on gear parameters deviations basically on gear root diameter through which the designer can decide the usefulness of gear for the further applications. The results of engineering calculations & simulation were found to be inline. This is a cost effective method to achieve the cost benefits of hob tool communization without affecting quality parameters.