The precise values of gear billet volume were obtained to evaluate the accuracy of above method.
Circle volume calculator software#
Solid modeling of cylindrical gear is constructed by taking advantage of Pro/E4.0 software as higher accuracy, feature modeling and parameter-driving (Jin et al. It is an accurate and convenient way to obtain spur gear billet volume by evaluating the accuracy with relative errors between average circle method and traditional method. Methods above may be far from the practical application and do not meet large-scale applications in spur gear cold precision forging.Ī new engineering method named average circle method is put forward to calculate the volume of spur gear billet on the basis of our long-term practice and experiment in this article. Up to now, there is no simple method to obtain gear billet volume precisely (Chen et al. ( 2009) proposed a thick wall cylinder model to take the reference diameter as bore diameter without considering gear tooth shape. ( 1996) suggested a trapezoidal tooth profile theory to obtain the billet volume in spur gear precision forging. 2012), but it is extremely complicated and will cost long modeling time.
Three-dimensional solid modeling is an accurate and feasible method to obtain the billet volume (Jin et al. Reference circle method is a traditional method to calculate the billet volume, which is not taken into account the clearances between the working teeth and tooth modification factors. This is because the billet volume is equal to the volume of the gear in cold precision forging. The change of billet volume will affect dimensional accuracy of the gear as is demonstrated by Xu and Chi ( 2000). In order to obtain the complete filling of the die cavity form, the billet is supposed to have the exact volume needed for the finished part (Behrens et al. 2014).Īs more and more types and sizes of forging gears are needed, the accuracy of billet volume plays an extremely important role in fully filling the die cavity during the cold precision forging of spur gear (Balendra and Qin 2000 Abrinia and Makaremi 2008). The recent trend of manufacturing spur gear is characterized by cold precision forging and enhanced strength of gear with lower cost and higher productivity in the mining machinery industry (Lee et al. which satisfies the requirements poorly in complex and bad environment of the coal mine (Jing and Xing 2006 Can and Misirli 2008 Lee et al. Using traditional machining method to manufacture spur gear has some drawbacks and insufficiencies, such as severe erosion and abrasion, poor strength and service life, lower transmission efficiency and huge material waste, etc.
and mainly used for the transmission of rotary motion between two shafts. Spur gears is commonly applied in the driving system of the mining machinery and equipment, such as scraper conveyer, gearbox, mining drilling and excavator, etc. It shows that average circle method possesses a higher calculation accuracy than reference circle method (traditional method), which should be worth popularizing widely in calculation of spur gear billet volume. Relative errors of the calculated and the experimental for obtaining the gear billet volumes with reference circle method are larger than those of the average circle method. Comparing with the accurate three-dimensional modeling method, the accuracy of average circle method by theoretical calculation was estimated and the maximum relative error of average circle method was less than 1.5 %, which was in good agreement with the experimental results.
Circle volume calculator series#
With this method, a series of gear billet volumes were calculated. For the purpose of precisely calculating the volume of cylindrical spur gear billet in cold precision forging, a new theoretical method named average circle method was put forward. Forging spur gears are widely used in the driving system of mining machinery and equipment due to their higher strength and dimensional accuracy.
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