Index

Note: Page numbers followed by “f” and “t” refer to figures and tables, respectively.

A Additive processes, 30 31, 47 50, 86 104.

See also Forming processes
Abrasive flow finishing (AFF), 128
AFF medium, 151 152 additive layer manufacturing processes,
AFF medium-related parameters, 153 93 104
gear casting, 47 49
Abrasive related parameters, 74
Abrasive water jet (AWJ), 71 74, 72f injection compression molding, 89 90
nozzle, 73 injection molding of plastic gears, 50
micropowder injection molding, 90 93
Abrasive water jet machining (AWJM), 32,
71 76 MIM, 86 88
advantages for gear manufacturing, powder metallurgy process, 49
75 76 Additives, 29
Adjacent pitch error, 203
history and developments, 71
machining of gears by, 74 75, 76f Advanced finishing processes, 144 164.
working principle, process mechanism, and See also Conventional finishing
process parameters, 71 74 processes
black oxide finishing, 162 164
Abrasives, 151
ABS. See Acrylonitrile butadiene styrene brush deburring, 159 161
(ABS) burrs, 154
CAVSF, 161 162
Accretion processes, 86 104
additive layer manufacturing processes, deburring TEM, 158 159
93 104 ED, 157 158
injection compression molding, 89 90 gear finishing
by AFF, 151 154
micropowder injection molding, 90 93
MIM, 86 88 by ECG, 151
Accumulated pitch error, 203 by ECH, 144 151
Accumulator, 72 73 WJD, 154 157
Aerosol, 115 116
Acrylonitrile butadiene styrene (ABS),
100 101 AFF. See Abrasive flow finishing (AFF)
Active profile, 199 AGMA standard. See American Gear
Manufacturers Association standard
Addendum, 20
(AGMA standard)
Additive layer manufacturing (ALM), 86
fused deposition modeling, 101 102, 101f, Alloy steels, 23t, 26
102f ALM. See Additive layer manufacturing
(ALM)
introduction, history, and development,
93 94 Alumina (Al2O3), 29, 135 137
selective laser sintering, 98, 98f, 99f Aluminum alloys, 23t, 28
steps for gear manufacture, 94 95, 95f Aluminum silicon alloys, 28
American Gear Manufacturers Association
stereolithography, 95 97, 96f, 97f
3DP, 99 101, 100f standard (AGMA standard), 204

219
220 Index

American National Standards Institute C

(ANSI), 204 Carbide cutters, 113
Analytical gear inspection, 205 212. See also Carburizing, 26, 169, 189 191
Functional gear inspection hardening, 26
macrogeometry measurement, 206 207, Case-hardened
206f, 207f gears, 189
microgeometry measurement, 207 212, steel gears, 181
208f Case-hardening, 26, 128, 135 137, 169,
pitch and runout measurement, 189 194. See also Flame hardening;
211 212 Induction hardening
profile and lead measurement, 208 211, of gear-teeth surfaces, 169
209f, 210f Cast iron, 22, 23t
Angle of obliquity, 20 Casting
Angular position, 215 216 process, 47 49
Angular velocity, 215 216 steels, 27
ANSI. See American National Standards techniques, 29
Institute (ANSI) Catastrophic gear failures, 127 128
ANSI/AGMA 2015 1-A01 standard, 205 Catcher, 73
Appropriate finishing process, 127 128 unit, 156
Archimedes, 1 2 Cathode gear, 148 150
Austenitic steels, 26 27 Cathodic arc deposition, 172
Automated AFF system, 154 Cavitation water jet shotless peening,
AWJ. See Abrasive water jet (AWJ) 187 189, 188f
AWJM. See Abrasive water jet machining CAVSF. See Chemically accelerated vibratory
(AWJM) surface finishing (CAVSF)
Axial gear shaving, 134 CBN. See Cubic boron nitride (CBN)
Axial hobbing process, 39 Center distance, 20
Ceramics, 23t, 29, 68, 88, 90 92, 98
form grinding, 135 137
B Chemical vapor deposition (CVD), 169,
Backlash, 20 172 173
Base diameter, 19 Chemically accelerated vibratory surface
“Base tangent”, 206 finishing (CAVSF), 144 145,
Bevel gears, 9 10, 204 205 161 162, 163f
Binder jet 3D printing, 99 Chordal tooth thickness, 198
Binder jetting, 99 Circular pitch, 20
Black oxide finishing, 162 164, 163f Cleaning, 146 148, 163
Blackening, 163 Clearance, 20
Boron carbide (B4C), 169 170, 173 CMM. See Coordinate measuring machines
coatings, 180 (CMM)
Brass alloys, 23t, 27 CNC. See Computer numerically controlled
Broaching (CNC)
of internal gears, 37, 37f Coarser abrasive grains, 141
process, 36 37 Coating, 33, 88, 113, 169, 171 176, 180 182
Bronze alloys, 23t, 27 coating of gear-teeth surfaces, 169
Brown gear, 87, 92 testing and inspection of gear coatings,
Brush deburring, 159 161, 160f, 162f 176 179
Brush geometry, 159 160 tribological characteristics of gears using
Burnishing, 110, 128, 142 various coating types, 180 182
dies, 142 vapor deposition or thin-film coating
gear, 142, 143f methods, 172 176
Burrs, 154, 157 Cold drawing, 30 31, 42 44
 Index 221

Cold roll forming of gears, 45 Cross-axes angle, 134

Cold-rolled gears, 128 Cross-helical gears, 4t
Complete face milling method, 56, 56f Crossed-helical gears, 13 14
Composite error total, 216 217 Cryogenic cooling, 109 112, 117 118
Composite gear inspection. See Functional Cubic boron nitride (CBN), 135 137
gear inspection Cup-shaped wheel, 137
Compression, 90 Curing errors, 103 104
Computer numerically controlled (CNC), 73, CVD. See Chemical vapor deposition (CVD)
144 Cyclex machining, 62 63
gear metrology, 207 208 Cycloidal curve, 17 18
instruments, 207 Cycloidal gears, 18
programing, 81 82 Cylindrical gears, 36 37, 204
Conical gears, 53 conventional manufacturing
ECH of, 149 151, 152f additive processes, 47 50
manufacturing by machining process, forming processes, 42 47
53 63 subtractive or material removal
generative machining processes, 55 61 processes, 35 42
nongenerative machining processes, Cylindrical gears, ECH of, 148 149, 150f
62 63 Cylindrical rods, 44
Conical-shaped bevel gears, 9 10 Cylindrical worm gear, 12
Constant-pressure gear honing, 138 140
Contact ratio, 20 D
Contour type induction hardening, 192 DC. See Direct current (DC); Dry-cutting
Control errors, 103 104 (DC)
Conventional black oxidizing, 162 163 De-powdering, 99
Conventional finishing processes, 31 32, Debinding, 87, 92
128 144, 129t. See also Advanced Deburring, 32 33, 128, 154, 156 157, 161
finishing processes brush, 159 161, 160f, 162f
catastrophic gear failures, 127 128 TEM, 158 159, 159f
gear burnishing, 142 Dedendum, 20
gear grinding, 135 138 Deep X-ray lithography (DXL), 107 108
gear honing, 138 140 Deforming processes, 104 107
gear lapping, 140 141 fine blanking, 106 107, 106f, 107f
gear shaving, 132 135 hot embossing, 104 106
gear skiving, 142 144 Demolding, 104
Conventional gear shaving, 134 Deposition, 172
Conventional manufacturing of cylindrical methods, 193 194
gears Destructive techniques, 176 177
additive processes, 47 50 “Deviation”, 204
forming processes, 42 47 Diagonal gear shaving, 135
subtractive or material removal processes, Diameter, 199
35 42 Diametral pitch (DP), 18
Conventional metallic gear manufacture, 29 Diamond-like carbon (DLC), 169 171, 173
Conventional shot peening techniques, 184 Die casting, 27 28, 30, 47 48
Conversion coatings, 171 Dielectric pressure, 80
Coordinate measuring machines (CMM), Dimensional parameters. See Macrogeometry:
207 208 parameters
Copying methods. See Form cutting method Direct current (DC), 144 145
Copying process, 65 DC-power-supply-related parameters, 150
Corrosion, 146 148 power supply system, 146
Coupling, 17 Dish-shaped wheels, 137
Crimped type filaments, 159 160 DLC. See Diamond-like carbon (DLC)
222 Index

Double helical gears, 8 9, 9f External gears, 37

Double-enveloping worm gear, 12, 13f External honing process, 138 140
Double-flank inspection, 213 215 Extrusion process, 44
flank contact, 213f extruded brass pinions, 45f
graphical representation of errors in gear
quality, 215f F
technique, 214f Face hobbing method, 57, 57f
DP. See Diametral pitch (DP) Face mill cutters, 56 57
Dry machining, 112, 118
Face milling method, 55 57
Dry-cutting (DC), 109 110 Face of tooth, 20
Dry-hobbing, 112 113 Face width, 20
benefits, 114, 115f
Failure Load Stage (FLS), 180 181
machine tool, 113f Fatigue, 167, 181, 183, 187, 189, 191
requirements for effective, 113 114 FDM. See Fused deposition modeling (FDM)
Dual-frequency process, 193 Ferrous metals and alloys. See also
Ductile iron, 22
Nonferrous metals and alloys
Duty cycle, 79 cast iron, 22
DXL. See Deep X-ray lithography (DXL) steel, 22 27
Field-controlled ECH, 146
E Film deposition, 175f
EAP. See End active profile (EAP) Fine blanking, 31, 43 44, 106 107, 106f,
ECF. See Electrochemical finishing (ECF) 107f
ECF/PECF processes, 145 Fine-edge blanking process. See Fine blanking
hybridization, 145 Finishing chamber, 148
ECG. See Electrochemical grinding (ECG) Fixed center distance method, 213
ECH. See Electrochemical honing (ECH) Fixed-setting face milling method, 56, 56f
ED. See Electrolytic deburring (ED) FL. See Flood lubrication (FL)
EDM. See Electric discharge machining Flame hardening, 193 194, 194f. See also
(EDM) Induction hardening; Mechanical
Electric discharge machining (EDM), 71 hardening
Electric motor, 72 73 Flank inspection, 212 213
Electrochemical finishing (ECF), 144 145 Flank of tooth, 20
ECF-related parameters, 150 Flat rolling functions, 45, 46f
Electrochemical grinding (ECG), 151 Flood lubrication (FL), 118
gear finishing by, 151 FLS. See Failure Load Stage (FLS)
Electrochemical honing (ECH), 32 33, 128 Fluoropolymers, 28
gear finishing by, 144 151 Forging, 29 31, 42 43, 47
Electrodeposition of gear/part material, 109 Form cutting method, 35 38
Electroless nickel coatings, 171 gear broaching process, 36 37
Electrolyte supply, 146 148 gear cutting on shaper, 37
Electrolyte-related parameters, 150 gear milling process, 35 36
Electrolytic deburring (ED), 128, 157 158, shear cutting process, 38
158f Form grinding of gears, 135 137
Electron-beam evaporation, 173 Form parameters, 199
Electron-beam PVD, 172 Form-cutting processes, 30 31
End active profile (EAP), 199 Formate
Environment-friendly lubricants, 109 110, formate-completing operation, 62
112 117 machining process, 62
Environment-friendly lubrication techniques, single-cycle operation, 62
119 120 Forming methods, 31, 42 43
Evaporative deposition, 172 Forming processes, 30, 35, 42 47. See also
External configuration of spur gears, 3 Additive processes
 Index 223

extrusion and cold drawing process, 44 Gear finishing, 110 111

gear forging process, 47 by AFF, 151 154
gear rolling process, 44 47, 46f by ECG, 151
stamping and fine blanking process, 43 44 by ECH, 144 151, 147f
141/2 composite system, 21 ECH of conical gears, 149 151
141/2 full-depth involute system, 21 ECH of cylindrical gears, 148 149
Friction Gear manufacturing, 29 33, 53, 197
coefficients, 171, 176, 178 advances in, 67
low-friction coating, 170 171, 181 additive or accretion processes,
Functional gear inspection, 212 217. See also 86 104
Analytical gear inspection deforming processes, 104 107
double-flank inspection, 213 215 hybrid processes, 107 109
single-flank inspection, 215 217 subtractive or material removal
Functional profile, 199 processes, 68 86
Fused deposition modeling (FDM), 86 sustainable manufacturing of gears,
FZG 109 120
back-to-back gear test rig, 176 177 advances in gear manufacturing and
gear test rig, 176 178, 180 finishing, 32 33
testing machine, 178 advantages of AWJM for, 75 76
ALM advantages for, 102 103
G conventional gear finishing, 31 32
Garnet, 74 conventional gear manufacturing, 30 31
Gases, 190 191, 193 laser systems for, 70 71
Gear accuracy, 197 203 by WSEM processes, 78f
gear tolerances and standards, 204 205 mechanism of material removal,
macrogeometry parameters, 198 199 80 82
measurement, 205 217 recent investigations, 82 84
analytical gear inspection, 205 212 working principle and significant process
functional gear inspection, 212 217 parameters, 78 80
microgeometry parameters, 199 203 Gear-teeth surfaces, 168
Gear coatings case hardening of, 169
methods, 171 176 coating, 169
testing and inspection, 176 179, 177f, 179t mechanical hardening, 169 170
types, 170 Gear(s), 1, 3
for gears, 170 171 advanced manufacturing processes for, 68
tribological characteristics of gears using broaching, 36 37
various coating types, 180 182 burnishing, 142, 143f
Gear engineering, 1 3 casting, 47 49
classification and gear types, 3 17, 4t coupling, 17, 17f
intersecting-shaft gears, 9 11 cutting on shaper, 37, 38f
nonparallel nonintersecting-shaft gears, design, 127 128
12 14 forging, 47
parallel-shaft gears, 3 9 grinding, 135 138, 136f
special gear types, 14 17 hobbing, 38 39, 40f
gear manufacture, 29 33 axial hobbing process, 39
gear materials, 21 29 radial hobbing process, 39
aluminum alloy, 28 and shaping technologies, 2 3
ferrous metals and alloys, 22 27 tangential hobbing process, 39
nonferrous metals and alloys, 27 28 honing, 138 140, 139f
nonmetals, 28 29 lapping, 140 141, 141f
gear terminology, 17 21, 19f laser system for manufacturing, 69f
gear wheel drives, 1 2 machining by AWJM, 74 75, 76f
Persian wheels’, 2f metrology, 197
224 Index

Gear(s) (Continued) G-ratio, 137 138

CNC, 207 208 Green manufacturing, 32
milling, 35 36, 36f Grinding, 31 32
planning, 38 42 gear, 135 138, 136f
rolling, 44 47, 46f wheel, 135 138
shaping, 38 40, 41f
shaving, 132 135, 132f, 133f H
skiving, 128, 129t, 142 144 Hardenability, 26
surface modification, 167 170, 168f
Hardened helical gears, 146
case hardening of gear-teeth surfaces, Hardening, 26
169 Heat-affected zones (HAZs), 70
coating of gear-teeth surfaces, 169
Helical gears, 4t, 7 8, 8f
gear coatings, 170 182 cutting process, 38
mechanical hardening of gear-teeth Helical rack-and-pinion arrangement, 7 8,
surfaces, 169 170 8f
surface property enhancement
Helix measurement, 210
flame hardening, 193 194 Helixform machining process, 62
gear surface modification techniques, Herringbone gears, 8 9, 9f
168 170 High-speed steel (HSS), 132
induction hardening, 191 193
High-strength wrought aluminum alloys, 28
PECVD, 175 176 Hobbing, 28, 39
pitting test, 178 179 Honing, 31 32, 83 84, 151
scuffing test, 178 gear, 138 140, 139f, 148 149
sputtering PVD, 173 175
honing-related parameters, 150
surface hardening of gears, 182 194 Hot embossing, 104 106
surface modification of gears, 167 168 capabilities, advantages, limitations, and
testing and inspection of gear coatings,
applications, 105 106
176 179 working principle, 104, 105f
vapor deposition or thin-film coating “Hourglass”, 12
methods, 172 176 HSS. See High-speed steel (HSS)
terminology, 17 21, 19f
Hybrid processes, 107 109
standard gear tooth proportions, 21, 21t LIGA, 107 109
tolerances, 204 205 Hybridization of ECF/PECF, 145
tooth size, 18, 19f Hydraulic parameters, 74
tooth Vernier calliper, 206
Hydraulic pump, 72 73
types, 35 36 Hydraulic pumping unit, 155 156
Generative grinding of gears, 137 Hypoid gears, 4t, 13, 14f, 56 57
Generative machining processes for conical
Hypoid pinion, 53 54, 56f
gears, 53 61. See also Nongenerative
machining processes for conical gears
face hobbing method, 57 I
face milling method, 55 57 ICM. See Injection compression molding
generation by interlocking cutters, 57 58 (ICM)
generation by revacycle cutters, 58 59 IEG. See Interelectrode gap (IEG)
planning generators, 61 Imaginary generating conical gear, 53 54,
shaping by two-tool generators, 59 61, 60f 54f
Generative processes, 30 31, 38 42 Index error, 203
gear hobbing process, 39 Induction hardening, 26, 191 193, 192f.
gear planning process, 40 42 See also Flame hardening; Mechanical
gear shaping process, 39 40 hardening
Geometric accuracy, 33, 119 120, 208 Injection compression molding (ICM), 86,
Geometric accuracy assessment, 33 89 90
 Index 225

capabilities, advantages, limitations, and form error, 202

applications, 90 and lead errors, 202 203
working principle, 89 90, 89f lead of helical gear, 202f
Injection molding, 28, 47, 86 87 measurement, 202 203
of plastic gears, 50 measurement, 208 211, 209f, 210f, 211f
cylindrical plastic gears, 51f Lead error, total, 202
dies, 50f LIGA. See Lithographie, galvanoformung and
Intensifier, 72 73 abformung (LIGA)
Interelectrode gap (IEG), 77 78, 145 146 Light amplification by stimulated emission of
Interlocking cutters, generation by, 57 58, radiation (LASER), 68
58f Liquid-based ALM processes, 93
Internal helical gear arrangements, 9 Lithographie, galvanoformung and abformung
Internal honing process, 138 140 (LIGA), 29, 107, 108f, 109
Internal spur gear, 3, 7f capabilities, advantages, limitations, and
International standards, 204 205 applications, 109
Intersecting-shaft gears, 4t, 9 11 microgear by LIGA process, 108f
Investment casting process, 48 49 working principle, 107 109
Involute curve, 17 18 Lithography, electroplating, and molding.
Involute gears, 18 See Lithographie, galvanoformung and
Involute profile errors, 201 abformung (LIGA)
Ion-nitriding. See Plasma: nitriding Location parameters, 199
Ionization efficiency, 174 175 Low-temperature black oxide finishing, 163
Iron copper steels, 27 Lubrication techniques, 109 110, 112 117
Iron nickel steels, 27
Isotropic surface finishing. See Chemically M
accelerated vibratory surface finishing Maag process, 40 42, 43f
(CAVSF)
Machine calibration, 208
Machine tool, 148
K Machine-related parameters, 154
Kinematic errors, 203 Machining process
conical gears manufacturing by, 53 63, 54f
generative machining processes for conical
L gears, 55 61
Lapping, 31 32, 141 nongenerative machining processes for
gear, 140 141, 141f conical gears, 62 63
tool, 140 Macrogears, 1
LASER. See Light amplification by stimulated Macrogeometry
emission of radiation (LASER) measurement, 206 207, 206f, 207f
Laser beam, 68 parameters, 198 199
intensity of, 69 70 Magnesium
Laser hardening, 26 alloys, 28
Laser machining die-cast alloys, 23t
ability of high power lasers, 68 Magnetron, 174
laser systems for gear manufacturing, sputtering, 174 175
70 71 Manufacturing processes, 63
working principle, process mechanism, and additive layer, 93 104
process parameters, 68 70 Marine transmissions, 47
Laser peening, 169 170, 186 187, 186f Martensitic grades, 26 27
Laser pulse, 187 Material erosion, 77
Laser systems for gear manufacturing, 70 71 Material removal processes
Lead, 199, 202 203, 202f AWJM, 71 76
angle/slope error, 202 laser machining, 68 71
226 Index

Material removal processes (Continued) Minimum quantity lubrication (MQL), 32,

spark erosion machining, 76 86 109 110, 115 117
Material removal rate (MRR), 140 assisted machining of gears, 115
MCT. See Minimal cooling technique (MCT) components, 116f
Mechanical hardening. See also Flame heat generation during machining, 116f
hardening; Induction hardening working principle and mechanism,
case-hardening, 189 194 115 117
cavitation water jet shotless peening, equipped gear milling, 118
187 189, 188f Miter bevel gears, 11, 12f
of gear-teeth surfaces, 169 170 Mitsubishi Heavy Industries Ltd, 113
laser peening, 186 187, 186f 16MnCr5 steel, 26
plasma nitriding, 190 191, 190f 20MnCr5 steel, 26
shot peening, 182 184, 183f Modern ED machine tools, 157
ultrasonic shot peening, 184 185, 185f Modified roll machines, 55
Mechanical honing, 145 Module (m), 18
Mechanical type hand-operated instruments, Molybdenum disulfide (MoS2), 169, 171, 173,
207 181
MEMS, 97, 106, 156 157 MoS2-doped Ti Al Cr N multilayer
Metal injection molding (MIM), nanocomposite wear-resistant coatings,
86, 86 88 182
capabilities, advantages, limitations, and MQCL. See Minimal quantity cooling and
applications, 88 lubrication (MQCL)
sequence of activities involved in, 87f MQL. See Minimum quantity lubrication
working principle, 86 88 (MQL)
Metallic materials, 21 22, 92, 109 MRR. See Material removal rate (MRR)
Metallic/ceramic powder, 91 μ-PIM. See Micropowder injection molding
Metrology, 197 (μ-PIM)
Micro-SEM, 78
Microgears, 70 71, 88, 90 93, 97f, 106 N
Microgeometry Nanocomposite coatings, 182
measurement, 207 212, 208f Nanoelectromechanical systems (NEMS), 1
parameters, 198 203, 200f NEMS-MEMS, 29
lead and lead errors, 202 203 Nanogears, 1, 29
pitch error and runout, 203 Nanostructured coatings, 182
profile and profile errors, 199 201 Natural fiber filaments, 160
Microinjection molding process, 50, 91 92 Nd:YAG-IR laser, 70 71
Microlubrication technique, 115 Near-dry machining, 112, 118
Micrometers, 206 NEMS. See Nanoelectromechanical systems
Micromold, 104 (NEMS)
Micropowder injection molding (μ-PIM), 86, Nitriding hardening, 26
90 93 Noise, 7, 31, 33, 127, 141, 156, 198, 203,
capabilities, advantages, limitations, and 215
applications, 92 93 intensity level, 156
microgear manufacture by, 91f level, 182
working principle, 91 92 Noncircular gears, 14, 53
Microsystem, 29 manufacturing of, 63 65
MIM. See Metal injection molding (MIM) shapes of, 15f
Miniaturization, 70 71 Nondestructive techniques, 176 177
Minimal cooling technique (MCT), Nonferrous metals and alloys, 27 28.
118 See also Ferrous metals and alloys
Minimal quantity cooling and lubrication copper alloys, 27 28
(MQCL), 118 Nongenerative grinding of gears, 135 137
 Index 227

Nongenerative machining processes for Pinion(s), 3

conical gears, 62 63. See also extruded brass, 45f
Generative machining processes for helical rack-and-pinion arrangement, 8f
conical gears hypoid pinion, 53 54, 56f
formate machining process, 62 spiral bevel, 53 54
helixform machining process, 62 Pitch, 203
template machining and cyclex machining, circle, 18
62 63, 64t error, 203, 203f
Nonmetallic materials, 21 22 measurement, 211 212, 212f
Nonmetals, 28 29 Pitting, 167 168
Nonparallel nonintersecting-shaft gears, 4t, test, 176 179
12 14 tribological characteristics of gears,
Nozzle(s), 156 180 182
AWJ, 73 75 PJP. See Plastic jet printing (PJP)
AWJM, 71 74, 72f Plain carbon steels, 23t, 26
diameters, 156 Planarization, 109
in extrusion, 101 102 Planning generators, 61, 61f
geometry, 69 70 Plasma
tooling, 156 157 gas, 186 187
nitriding, 190 191, 190f
O Plasma-enhanced chemical vapor deposition
One-way AFF, 153 (PECVD), 173, 175 176, 176f
Orbital AFF, 153 Plastic gears, 29
injection molding of, 50
Plastic jet printing (PJP), 101 102
P Plastics, 23t, 28
Parallel-shaft gears, 3 9, 4t Plunge gear shaving, 134 135
Pawl-and-ratchet mechanism, 16 POD. See Pin-on-disc (POD)
PC-based CAD/CAM software, 74 75 Polyamides, 28
Peak current, 80 Polycarbonates, 28
PECH process. See Pulsed electrochemical PolyJet printing, 100 101
honing process (PECH process) Polymer coatings, 171
PECVD. See Plasma-enhanced chemical Polytetrafluoroethylene (PTFE), 50, 171
vapor deposition (PECVD) Postsintering, 88
Pedestal ball bearings, 148 Pot broaching method, 37
Peening Powder metallurgy, 47
cavitation water jet shotless, 187 189 gears, 49f
laser peening, 186 187 process, 49
shot peening, 182 184 Powder-based ALM processes, 93 94
ultrasonic shot peening, 184 185 Powder-pressing technique, 27
Perpex, 148 Precipitation hardening (PH), 26 27
Persian wheels’, 1 2, 2f Precision, 31 32, 149 150, 171, 204
PH. See Precipitation hardening (PH) Pressure angle (ϕ), 20
Phosphate coatings, 171 Primary electrons, 80 81
Photopolymer, 95 96, 100 101 Profile
Photoresist material, 107 109 angle error, 199
Physical vapor deposition (PVD), 169, 172 and errors, 199 201, 201f
electron-beam, 172 functional profile, 201f
sputtering-based, 173 gear tooth profile, 201f
PIM. See Metal injection molding (MIM) form error, 199
Pin-on-disc (POD), 176 177 measurement, 208 211, 209f, 210f, 211f
Pinion rods. See Cylindrical rods Profile error, total, 199
228 Index

Profiling methods. See Form cutting method Sector gear, 15 16, 15f
PTFE. See Polytetrafluoroethylene (PTFE) SED. See Spark erosion deburring (SED)
Pulse duration, 79 Selective laser sintering (SLS), 86, 98, 98f,
Pulse frequency, 79 99f
Pulse interval, 79 SEM. See Spark erosion machining (SEM)
Pulse-off time, 79 Shaper, gear cutting on, 37
Pulse-on time, 79 Shaping
Pulsed DC power source, 145 146 of noncircular gear, 65
Pulsed electrochemical honing process (PECH by two-tool generators, 59 61, 60f
process), 144 146 Shaving
Pulsed laser deposition, 172 cutters, 132, 134
Pump power, 155 156 gear, 132 135, 132f, 133f
Pumping unit, 72 73 Shear cutting process, 38
PVD. See Physical vapor deposition (PVD) Short wavelength X-rays, 108
Shot peening, 169 170, 182 184, 183f
R ultrasonic, 184 185, 185f
Rack and pinion configuration, 3, 4t Shotless water jet peening, 169 170
Rack shaving, 132f, 133 Silicon carbide (SiC), 135 137
Radial hobbing process, 39 Single pitch error, 203
Radio-frequency discharge-based PECVD Single-enveloping worm gear, 12, 13f
(RF-PECVD), 176 Single-flank inspection, 213, 215 217
Rapid manufacturing (RM), 93 94 basic operational principle, 216f
Rapid prototyping (RP), 28, 93 94 flank contact, 216f
Rapid tooling (RT), 93 94 typical output of a single-flank
Ratchet wheel, 16, 16f tester, 217f
Raw material preparation, 86, 91 Single-setting face milling method,
Reaction, PVD, 172 56
Reference circle, 18 Single-side face milling method, 56
Reference pitch, 20 Sintered steels, 27
Revacycle cutters, 58 59, 59f Sintering, 87 88, 92
RF-PECVD. See Radio-frequency discharge- Skiving gear, 142 144
based PECVD (RF-PECVD) SLA. See Stereolithography (SLA)
RM. See Rapid manufacturing (RM) Slipping, 1
Robotics, 18 SLS. See Selective laser sintering (SLS)
Room temperature blackening, 163 SOD. See Stand-off-distance (SOD)
Root diameter, 19 Sodium chlorate (NaClO3), 146 148
Rotary fan nozzles, 156 Sodium chloride (NaCl), 146 148
Rotary shaving, 132 134 Sodium nitrate (NaNO3), 146 148
Round rolling of gears, 45 47, 48f Solid-based ALM processes, 93
RP. See Rapid prototyping (RP) Sonotrode, 184 185
RT. See Rapid tooling (RT) Span, 198 199, 206
Runout, 203, 203f Spark erosion deburring (SED), 128
measurement, 211 212, 212f Spark erosion machining (SEM), 75 86
advantages, capabilities, and limitations,
S 84 86
manufacturing of gears by WSEM
SAE 8620 steel, 26
Sand casting process, 48, 48f processes, 78 82
SAP. See Start active profile (SAP) material erosion, 77
micro-SEM, 78
Screw gears. See Crossed-helical gears
SEM-based machining processes, 85
Scuff testing, 176 177
Scuffing, 167 Spark gap voltage, 79 80
test, 178 Spin hardening, 193
 Index 229

Spiral bevel, 56 57 T
gear test, 180 181 Taguchi technique, 120
gears, 4t, 10, 11f, 53 54 Tangential gear shaving process, 134
Spiroid worm and wheels, 182 Tangential hobbing process, 39
Spline(s), 16 17, 16f, 35 37, 39 TEM. See Thermal energy method (TEM)
Spur gears, 3, 4t, 43 44, 44f, 47, 146 Template machining process, 62 63
Spur rack, 3, 7f Template method of manufacturing
Sputter deposition, 173 noncircular gears, 65
Sputtering Tessellation, 94 95
processes, 173 Thermal energy method (TEM), 158
Sputtering PVD, 173 175, 174f, 175f deburring, 158 159, 159f
Stainless steels (SS), 23t, 26 27 Thermoplastics materials, 28
Stamping process, 43 44 Thermoset materials, 28
Stand-off-distance (SOD), 69 70 Thin-film coating methods, 172 176
Standards, gear, 204 205 Threaded wheel, 137
Start active profile (SAP), 199 Three dimensional printing (3DP), 28, 86,
Static torque, 177 178 93 94, 99 101, 100f, 103 104
Steel, 22 27, 23t Threshold force, 135 137
Stereolithography (SLA), 86, 93 97, 96f, 97f Tip diameter, 19
STL. See Stereolithography (SLA) Titanium aluminide (TiAlN), 113
Straight bevel gears, 4t, 10, 10f Titanium cyanide (TiCN), 113
Straight gears, 53 54 Titanium nitride (TiN), 113
Straight type wire filament brushes, 159 160 Tolerance, 204
Substrate, 107 108 Tool feed rate, 80
Subtractive and/or material removal Tooling unit, 156
processes, 30, 35 42 Tooth
form cutting method, 35 38 surface material, 183
generative processes, 38 42 thickness, 20, 198, 206 207
Subtractive removal processes tooth-to-tooth error, 214 217
AWJM, 71 76 tooth-to-tooth method, 193
laser machining, 68 71 toothed wheel, 1 2
spark erosion machining, 76 86 Top land, 20
Sunderland process, 40 42, 42f “Total transmission error curve”, 216 217
Superfinishing. See Chemically Transmission error, 215
accelerated vibratory surface Transparent polymer, 148
finishing (CAVSF) Tribological characteristics of gears, 180 182
Surface coating(s), 170, 182 Tubing, 72 73
Surface conditioning, 163 Tungsten carbide carbon (WC/C), 169, 171,
Surface hardening of gears, 182 194 173, 180 181
mechanical hardening, 182 189 20 full-depth involute system, 21
Surface treatment techniques, 2 3 20 Stub involute system, 21
Sustainable manufacturing, 32 Two standard test-gear geometries, 178
of gears, 109 120 Two-way AFF, 153
challenges and opportunities, 110 112
dry-hobbing, 112 114
environment-friendly lubricants and U
lubrication techniques, 112 117 UBM sputtering. See Unbalanced magnetron
house of sustainability, 111f sputtering (UBM sputtering)
MQL assisted machining of gears, Ultra-short pulse durations, 70
115 117 Ultrasonic
recent investigations, 118 120 peening, 169 170
Synthetic fibers filaments, 160 shot peening, 184 185, 185f
230 Index

Ultrasonic-assisted abrasive flow finishing mechanism of material removal, 80 82

(US-AFF), 128, 153 recent investigations, 82 84
Unbalanced magnetron sputtering (UBM working principle and significant process
sputtering), 175 parameters, 78 80
Underpass gear shaving process, 134 mechanism of machining of gears by SEM
and, 81f
V Wire tension, 80
Vapor deposition methods, 171 176 WJD. See Water-jet deburring (WJD)
WJM. See Water jet machining (WJM)
“Variable center distance method”, 213
Vegetable oils, 112 Working depth, 20, 21t
Vibration, 7, 178, 184 Workpiece
gear, 148 150
Volume ratio, 137 138
workpiece-related parameters, 150, 153
Worktable, 73, 79 80
W Worm and worm wheel, 4t
Water jet machining (WJM), 71 74, Worm gears, 12, 204 205
154 155 Worm wheel. See Worm gears
Water jet unit, 73 WSEM. See Wire spark erosion machining
Water-jet deburring (WJD), 128, 154 157 (WSEM)
Water-lifting devices, 1 2
Wear, 21 22, 127 128
low-speed wear tests, 180 X
modes, 180 181 X-ray mask, 107
wear resistance, 192
wear-resistant case, 169, 189
wear-resistant coatings, 182 Z
ZF wear test, 178 Zero bevel gears, 11, 11f, 56 57
Whole depth, 20 Zero-backlash gear honing process, 138 140
Wire electric discharge machining (WEDM). Zero-setup gear deburring, 161
See Wire spark erosion machining Zinc, 28
(WSEM) die-cast alloys, 23t
Wire feed rate, 80 zinc aluminum alloys, 28
Wire spark erosion machining (WSEM), 63, Zirconia powder (ZrO2), 29
65, 76 77 Zirconia toughened alumina (ZTA), 97
manufacturing of gears by processes, 78f Zn 22Al alloy, 28