Gleason Bevel Gear Cutting Team Face Hobbing Design & Development Generally, this paper describes the

Face Hobbing process using Gleason PHOENIX Hypoid Generators and the TRI-AC Cutter. The assumption is further made that the calculation of the design and Summary of Machine Settings will be made using the computer program(s) (T2000) available either at Gleason, as an On-Line time sharing basis or Leased from the Gleason Works. Face Hobbing is a method of manufacturing Bevel & Hypoid gear sets which uses a Face Hob style cutting tool. This method differs from the more traditional Face Milling (5-Cut) method in several areas encompassing both the design and development of gear tooth forms. It is, as the name implies, a hobbing method and therefore the teeth of the gear(s) are cut with a continuous index or rotational action. In this process, the cutting tool, the workpiece, and the position of the center of the tool must all move in a correct timed relationship. Face hobbing is also a "Completing" method, or one in which the gear teeth are cut in a single chucking. A special "Face Hob" cutting tool which is generally unique for each gear tooth design is used. The cutting edges of these tools are relief ground in the sharpening process, rather than on the front face as is common in the Face Mill method. In addition, a gear manufacturer grinds the desired specification on the tool, allowing for a change in specification as desired for development. Since it is a hobbing method, the gear tooth design also has some unique features. Face Hob gear designs use a parallel depth concept, or have teeth in which the face, pitch, and root angles are generally all in the same plane. It is, however, possible to modify the Face and Root Angles somewhat to tip the gear teeth about the Pitch Cone Axis. Gear Tooth Design In general, the same basic design parameters used in traditional Face Mill designs should be observed when establishing tooth proportions. However, since the tooth design is based upon a parallel depth, there are several inherent features which need special attention. In this case, both members will have tooth taper in the lengthwise direction. This feature often results in very narrow toplands at the toe end of the teeth. In some cases it may be necessary to manufacture the blanks with a secondary face angle to maintain reasonable topland values. A second caution is that since the tooth form is made with parallel depth proportions, this type of design is more susceptible to undercut at the toe end of the pinion tooth. The designer needs to observe these features and revise proportions if necessary early in the process. If necessary, it is acceptable to tilt the pitch plane of the hypoid gear in the design process. In the Face Hobbing method it is very important to observe that adequate clearance exists in the tooth proportions. In addition, the cutter edge radius should be observed to assure that an interference condition does not exist. Often, the Face Hobbed design is reported to be stronger than many traditional designs. This is generally attributed to a number of factors related to the face hob design. First is the relatively small cutter diameter used in this process. This factor produces a "Small Cutter Effect" design. The rules used to establish a desired cutter diameter to gear design relationship are based upon the term "Ratio of Involute to Mean Cone" dimension which is calculated on the Dimension Sheet. For a desirable "Small Cuttter Design" strength advantage, this dimension should be in the range of 1.1 to 1.3. Smaller values will result in increasingly difficult to develop and control tooth forms, and larger values although resulting in easier to develop tooth patterns tend to reduce maximum strength capabilities. A second factor relates to the fact that Face Hobbing is a completing method. As such, the cutter edge radius which generates the tooth fillet

radius will always form a smooth transition from the tooth profile to the root area of the tooth. In the Face Hobbing method an additional factor is that the cutting tool is manufactured specific to a particular design which also results in the use of the optimum or largest cutter edge radius and maximum strength. A general observation related to strength characteristics indicates that Face Hobbed designs may result in as much as a 30% increase in strength when compared with traditional Face Mill (Multi-cut operation) manufactured parts. As indicated above, the basic design factors used in traditional gear designs should be observed. A course pitch design may show some strength advantage while a finer pitch design tends to be smoother operating and therefore offer some reduced gear noise tendencies. In the design phase, the Engineer does not have many terms to work with to evaluate this effect. The one area which will indicate some degree of acceptability is in the terms identified as "Contact Ratios". In Bevel and Hypoid design we work with three values identified as contact ratios, the Transverse (Depthwise), the Face (Lengthwise), and the Modified Contact Ratio. At the design stage, these values should be considered as the maximum obtainable for the particular set of parameters determined as the tooth proportions. It is suggested that the following criteria be used for guidelines to obtain a smooth operating (Quiet) design. The Transverse Contact Ratio should at least approach a value of 1.000, although acceptable designs have been manufactured with smaller values. The Face Contact Ratio should be a minimum of 1.500 with a preferred value of 2.000. The Modified Contact Ratio is perhaps the most significant of these factors as it reflects the combination of operation in both the depthwise and lengthwise directions. The Modified Contact Ratio should be at least 2.000, however, experience shows that the best designs for smoothness and minimum noise result when this factor is in the range of 2.200 to 2.300.

In many applications it is desirable to design gear sets to exhibit equal life rather than equal strength. With an equal life design, we sacrifice some strength or life of the gear member to increase the life of the pinion member. Since the pinion member will operate at more cycles than the gear by the ratio of numbers of teeth, this can be a desirable condition if we anticipate that the gear set will operate the number of cycles at a high enough load such that it will eventually fail. Traditional designs have been made with a Stress Balance of 0.18 for Equal Life. We have found through experience that the preferred strength balance for Face Hob designs in the range of 0.22 to 0.25. The designer must also evaluate the gear geometry to assure practical manufacture of the gear set. In addition to the previously mentioned parameters, the cutter blade point width is a primary factor in determining the cutter life. The lengthwise tapered tooth designs often lead to designs with narrow cutter point widths. This factor along with increases in tooth depth to achieve desirable contact retios can lead to very narrow cutter blade point widths. It is recommended that a minimum cutter blade point width of 0.040 ( 1.02mm) be maintained to achieve reasonable tool life. Both members of a Face Hobbed gear set could be cut with generated tooth forms. However, There will be a cutting time advantage if the gear member is manufactured as a Non-generated member (FORMATE). If the gear set ratio is 2.20 or larger it is therefore recommended that the gear set be produced with a Non-generated (FORMATE) gear member. Gears manufactured by this process are cut with a plunge operation and no generating roll. Summary Calculation The calculation of the summary or a set of conditions governing the cutting tools and machine settings is obviously an important step in the gear manufacturing process. It should be noted that what is considered the calculation of the summary actually involves several steps which allow observation of the operating characteristics of the gear teeth to manufactured. Of primary importance is the TCA or Tooth Contact Analysis. The TCA allows the Engineer to evaluate and modify parameters affecting the operating characteristics of the gear teeth to be manufactured. The characteristics of a Face Hob gear design observed on the TCA appear somewhat different than a typical traditional gear design. The most apparent difference is the Bias or path of contact observed in the Face Hob design. It is an inherent characteristic of the Face Hob gear design to show a Bias "IN" path of contact on both sides of the teeth. This Bias In condition can be controlled to some extent with parameters determining the Imaginary Generating Gear and the shape of the cutting tools to be used. However, before forcing the gear design to appear to have a "Traditional" tooth contact pattern, it should be understood that the Bias In tooth contact pattern seen in these type of designs may be an advantage and generally results in good operating characteristics. Typically, it has been found that the normal Drive side (Concave Pinion and Convex Gear tooth) is satisfactory with a significant amount of Bis In. From an operational standpoint, the normal Coast Side also operates in a satisfactory mode with a significant mount of Bias In, but since a larger amount of small cutter characteristic is observed in coast side tooth contact patterns, this factor sometimes leads to problems in the lapping process. It is therefore recommended that the Coast Side be modified to have slightly less Bias In than would be allowed on the Drive side. Desirable characteristics for the Bias conditions are shown in the TCA Fig. 1. The observed tooth contact patterns are accomplished by manipulation of various parameters in the Summary/TCA calculation. These parameters and the effects are listed below in the text below the figure. Pattern Length Factor - Changes the length of the tooth contact pattern on both sides of the teeth. As a completing method, this is accomplished by a change in the cutter blade angle(s) of the pinion member. Therefore, if preliminary cutting has already been done a new cutter specification for the pinion member must be manufactured. Blade Curvature - Applies a curvature on the cutter blade along the pressure angle, identified in the calculations as Rho. The effect of this change is a direct profile change applied to the gear tooth development. Typically, some value of profile curvature is used on the gear member. Since TOPREM is used on the pinion member it is suggested that curvature (Rho) not be used unless a satisfactory development can not be made with curvature on the gear cutter only. In

cases where the cutter has both TOPREM and blade profile curvature extra care must be taken to insure a good blend of the blade profile where it joins the TOPREM (protuberance).

Fig. 1

Delta Gamma X (x) - Profile Change (Pinion Member) accomplished with a change in the pitch angle of the Imaginary Generating Gear. A positive value (+) will introduce Bias-In and Profile-Out on both sides of the tooth. Delta Psi () - Spiral Angle Change (Pinion Member) appears mainly as a Bias change. A Positive (+) value will introduce Bias-In, Profile-In on the O.B. (Drive Side) Bias-Out, Profile-Out on the I.B. (Coast Side) Delta Ax (Ax) - Bias Change (Pinion Member) accomplished by a change in the cone distance of the Imaginary Generating Gear. A Positive (+) value will introduce Bias-In, Profile-In on the O.B. (Drive Side) Bias-Out, Profile-Out on the I.B. (Coast Side) Cutter Radius Change (Rp) - Allows a change in the length balance from one side of the tooth to the other. The change used should not be more than 0.050" (1.27mm) and a positive (+) value will lengthen the O.B. (Drive Side) and shorten the I.B. (Coast Side). It should be noted that these changes affect both the Bias and the rolling motion error (Profile) as described on the TCA. The rolling motion error is an indication of the smoothness of operation of the gear

set, and therefore an important factor for good gear design. It is suggested that the rolling motion error be adjusted in the TCA phase of calculation to result in similar curves at Toe, Mean, and Heel (note that this is not always possible), and be in the range of 30 to 40 microRadians to the crossover point for motion transfer from one pair of teeth to the next. In addition, it has been found that Face Hobbed gear teeth tend to exhibit much longer patterns (E/P) after the heat treatment operation. Therefore it is important to adjust the length in the soft state with observation of the Bias and E/P characteristics. For an average Automotive Gear Size of 8.000" (200mm) Pitch Dia. it is suggested that TCA soft lengths of Drive E = 0.050" - 0.055" (1.27 - 1.40mm) and Coast side length of E = 0.040" - 0.045" (1.01 - 1.14mm) will result in typically good process characteristics. For reference, test machine values are: Soft cut =0.040 - 0.045" (1-1.14mm) Hard (Unlapped) = 0.020-0.025 (0.5-0.63mm) Hard Lapped (final lengths) = 0.005 - 0.010" (0.13-0.0.25mm) TOPREM is a result of a protuberance manufactured on the cutter blades. Typically, TOPREM is used on the pinion member cutting blades and allows a relief at the top of the gear tooth and the root of the pinion tooth. This relief helps to reduce the possibility of interference which might occur during the lapping process. Since Face Hobbed gear sets tend to lap somewhat faster than traditional gears, it is suggested that additional TOPREM be used. TOPREM is identified with a combination of letters (ie. AJ, BK, etc.). The first letter in this set refers to the TOPREM length or protuberance depth, and the second letter refers to the angle of protuberance with respect to the blade pressure angle. The length of TOPREM is determined with respect to the depth of the tooth being cut. Tables of these values may be found in the calculating or computer input instructions. While any of the three standard values may be used, it is suggested that the largest TOPREM Angle be used for Face Hobbed gear designs. The three values used for TOPREM Angle are J = 2.4 Deg., Y = 3.5 Deg, and the recommended K = 4.5 Deg. The final decision as to the best amount to be used should be made in the development phase of the process. After the lapping of the gear teeth a small amount of TOPREM should still be apparent when the parts are rolled for contact pattern in a roll tester. In any event, the lapping should not result in hard lines or interference along the top of the gear and root of the pinion tooth. TRI-AC Cutter Slot Position The Gleason Face Hobbing method uses TRI-AC cutting tools. These cutter blades are unique in that they are manufactured with a slot in the front face of the blade to allow for a different and more correct rake angle on the clearance side of the blade. Use of this slot allows the use of only two blade specifications in each blade group, and generally more blade groups in a given size cutter style. Ultimately, these features can lead to higher production rates and more efficient cutting cycles. The blade slot position is very important for the correct operation of the blades and desirable cutter life conditions. Generally, each design will have a specific blade slot position unique to that particular set of circumstances. This value is detailed on the TRI-AC Blade description and Summary pages for the Face Hobbing design. Manufacture of the TRI-AC cutter blades requires that the Blade Slot Position should be within 0.005" (0.13mm) of the value described on the Summary. Even though these values are unique to a specific design, it is possible to manipulate the blade slot position to some extent with development parameters available in the computer program. Changes in the Pattern Length (accomplished with Blade Angle Changes), Balance of Pattern Length (Accomplished with the Cutter Radius Factor), and changes in cutter point width will all cause changes in Blade Slot Position. These

factors will, of course, also change either the design or the development as well. However, as an initial trial this cutter consolidation may be completely acceptable. Cutter Grinding (Gleason 300CG Blade Profile Grinder) The Gleason 300CG Blade Profile Grinder is used to make the initial blade specification as well as sharpen the blades after use. The settings for the No. 300CG machine are calculated as a part of the Summary and printed in a standard format. The majority of the blade details can be changed or revised in Blade Grinding with machine settings. A part of the development process is related to modifications to both the cutting machine setup and cutter blade geometry to accomplish the best possible cutter life. Although research continues, the following parameters are currently advised to effect the best cutter life in the average design. The Blade Top Relief Angle is a variable determined by the fixture used to hold the blade in the grinding machine. Fine Pitch TRI-AC Blades should be ground using a fixture which allows a 24 degree Top Relief when mounted in the cutter body (19.58 Deg. in the grinding process). Recent trials have also indicated that side relief angles larger than initially used for the system are recommended. The current version of the Gleason T2000 Computer Program will calculate the latest recommended blade geometry. Our current recommendation is that Primary Land and TOPREM on the Clearance Side of the Blade be used on pinion cutters. As a hobbing process, the accuracy and control of the cutter blade is extremely important to consistancy of part geometry from one cutter to another. Experience indicates that the blade grinding should be controlled so that the blades use in production are within the tolerances described below: Profile Tolerances for TRI-AC Blades (300CG Profile Grinder) Nominal Radius Blade Pressure Angle Alike within one set 51mm-105mm 0.0002 0.005mm +/-0.0002 +/-0.005mm +/-0.001 +/-0.025mm +/-0.002 +/-0.050mm +/-0.001 +/-0.025mm +/-0.0005 +/-0.013mm 0.0005 0.013mm 125mm-175mm 0.0003 0.008mm +/-0.0003 +/-0.008mm

From set to Set Clearance Angle Blade Top Width Blade Distance Actual Size Alike within one set Actual Size

Variation within one set Machine Cycle for Face Hobbing

The actual machine cycle used in the PHOENIX Hypoid Generator to manufacture face hobbed gear sets is calculated in the T2000 computer program. The values input at the machine control define chip loads of the cutting tool and rates at which the machine will plunge or roll as the case may be. These rates, as seen in the Summary and/or machine control are a result of a set of values input in the Summary calculation computer program. The actual machine cycle used by the PHOENIX Cutting machine depends on the type of part being cut. When cutting a Non-generated Gear member, the machine cycle utilizes a plunge feed only. Note that since this is a hobbing process, the cutter and workpiece must also roll together during the cutting operation. In the cycle for Non-generated gears, four plunge rates and two cutter speeds are normally used. The machine control input (given on the Summary of Machine Settings) identifies the rates used in the cycle with a combination of Feed Position and End Chip value. The feed position values are amounts away from full depth, and the chip load in size of the chip removed by the tip of the cutter blade. The PHOENIX Machine control system utilizes the feed position and chip load values to determine a continuously changing feed rate, from one of these points to the next, at the roughing cutter speed, through the Third Feed position. Upon reaching the Set-In Position, the machine backs out a small amount, the cutter speeds up to the finishing RPM, a fast feed is used to bring the cutter position back into the Set-In value away from full depth, then the Fourth Feed End Chip value is used to determine a constant feed rate to a full depth position. At full depth, the machine position is caused to Dwell so that all cutter blades will pass through all tooth slots. The machine setting values to allow the proper machine positions and speeds are calculated within the Summary Calculation computer program. The End Chip and Feed Position values can be modified manually at the machine to enhance cutter life and cycle timing events. When cutting the pinion member or a generated gear, the machine cycle varies somewhat from that used on a Non-Generated Gear. In the typical pinion operation, the cycle consists of three different portions. The first part of the cycle is a plunge. The second part of the cycle is a roll at roughing feeds and speeds to rough out the tooth slot, and the third part is a finishing roll at feed and speeds selected to give the desired tooth surface finish and gear quality required by the application. During the Initial portion of the pinion cutting cycle, the plunge is similar to the cycle used for the non-generated gear member. The plunge position, Feed Positions, and End Chip values are described on the Summary of Machine Settings. There are Four End Chip feed rates described on the Summary. During the plunge portion of the cycle, the machine varies in feed rate using the four plunge positions and end chip values and the first or roughing cutter speed to the whole depth less the Set-In value. Upon reaching the roughing depth, the cutter and workpiece roll (Cradle Roll) to the heel of the tooth to rough out the entire tooth slot. During this roughing roll, the roll rate may be changed three times to balance the chip load (Variable Roll Positions and Rates on Summary). The changes in roll rate take place as a ramp function with constantly changing rates of roll from one position and rate to the next as listed on the Summary. At the end of the roughing roll, the cutter will Set-In, Set-Over to balance the amount of stock removed on both sides of the tooth slot (both Summary Settings), the cutter speeds up to finishing speed, and the machine rolls (Cradle Roll) back to the other end of the tooth. The cutter chip load and surface finish of the tooth (Cutter Flats) are controlled by the Return Roll Rate listed on the Summary of Machine Settings. Typical Feed and Speed rates for an 8.000 (204mm) Pitch Diameter Hypoid gear set are described on the sample Summary of Machine settings which is included in this paper. It should be noted that the values shown for feeds and speeds and therefore cutting time are Default values from the computer calculation program. These are starting values for a given gear design and may require modification for the development of desired tooth surface finish, cutter life, and other operating characteristics of the gear application. Cutting the First Part(s) Although the computer program calculates machine and cutter specifications to very exacting detail, often minor adjustments are required when cutting the first parts.Although the Summary calculation programs check for gross machine limitations, they do not take into account actual position of the machine components and their relationship to the part being cut. It is therefore possible to calculate a Summary of Machine Settings which would not be possible to utilize due to interferences of the machine components

or tooling (Note that the Summary program(s) do not identify the tooling or part mounting distance dimensions). A software program configured to be used in a Personal Computer allows a number of features not found in the basic computer program. The PHOENIX P.C. Program allows among other things, the ability to check for arbor limits with the input of actual part and arbor length dimensions. If this program is not available or not used, each new job should be set up in the cutting machine and the position of the machine viewed at all positions of the cutting process to verify that the machine can physically go to the necessary positions and not have interference. In addition to the possibility of machine frame and guard interference as described above, the possibility exists that the toe end of a part (normally the pinion member) may interfere with the front face of the cutter body. Currently, there is not a computer program available to evaluate this possibility. Therefore it is suggested that a trial be conducted at the machine using the cutting set-up (Summary), the tooling and blank being used for the job, and a cutter head with no blades. The following procedure will allow check of possible interference: 1. Install the Arbor, a Blank, and Cutter Head in the PHOENIX Cutting Machine. 2. Input the Summary of Machine Settings including the Mounting Distance and Arbor Distance to be used. 3. Move the Machine to Center of Roll Position and Jog to Full Depth (Z-Axis). 4. At Full Depth Jog the machine to the heel position (V-Axis, minus direction) and watch closely for interference of the blank and the front face of the Cutter Body. 5. If it appears that interference will occur, the Cutter Reference Height should be increased. If the Cutter Reference Height needs to be Increased, the Height of the Cutter Blades Above the Head, a Summary dimension for build of the cutter, should be increased by the same amount plus a comfortable clearance value. When cutting a non-generated gear member there are two areas of concern. The first is chatter which appears as vertical marks along the tooth. The second item is the tooth spacing or accuracy of the placement of the tooth. In either case, the gear cutting 4th Feed End Chip and the Set-in may need to be reduced. These values are calculated to obtain maximum production cycle for a particular set of circumstances, but practical considerations indicate that values for the 4th Feed End Chip between 0.0005"-0.0008" (0.013-0.020mm) and a Set-in value of 0.008" (0.20mm) will reduce spacing or chatter issues. The pinion member, which is always generated, may show an area of non-cleanup. This phenomena occurs between the roughing and finishing roll in the cutting process. Normally this effect will be observed on the concave side of the pinion tooth where an area near the top of the tooth will appear to have a very rough surface. If this effect is present, increasing the Set-over and/or decreasing the Z-Axis Feed Angle will eliminate the problem. Initially, a value of 0.005" (0.13mm) should be introduced or added to the SetOver. This value should not be increased more than 0.010" (0.25mm). If the small amount of Set-Over does not affect a correct clean up condition, decrease the Z-Axis Feed Angle in increments of 1 Degree to obtain balanced stock removal. Development of the Tooth Contact Pattern As both a completing and hobbing method, the development of tooth contact patterns varies somewhat from the more traditional bevel and hypoid gear tooth development. Basically, the shape and length of the tooth contact pattern will be established in the calculation of the summary (TCA and cutter specifications). The development process for this method includes First Order pattern position, adjustment of the machine cycle to clean-up the tooth, and later modifications of tool geometry and machine cycle to effect the best tool life. Generally, the gear member is cut "Standard". This means that the gear is cut to proper size as identified on the "Summary" and then the tooth form checked and modified as necessary using G-AGE/CMM programs. It is extremely important that the teeth of both members are cut at the correct size before any corrections are made.

Experience gained in the mid size automotive hypoid gear design area (ie. 8.000", 204mm) indicates that a typical gear set of this type uses a soft position of the Drive Side pattern (Convex Side of the Gear Member) approximately central lengthwise on the tooth. After heat treatment the pattern would be expected to remain in nearly the same position, although it tends to lengthen somewhat. The Coast Side tooth contact pattern tends to move much more during the heat treatment process. It has been found that the best starting position for this side is central toe position, and 0.010" (0.25mm) high. This pattern will appear to be small and extremely high when run at the theoretically correct mounting position. Normally the operator will need to check the pattern by adjusting the pinion mounting position by the 0.010" or 0.025mm (-0.010 Pinion Cone Position). After the heat treatment operation, the pattern may still tend to be slightly high and usually will move somewhat toward the center of the tooth.The preferred position is high on the gear member rather than low (for lapping purposes). After initial cutting of both the gear and pinion members to summary settings, and observing the tooth contact pattern positions, it will usually be necessary to "Develop" the pinion tooth form to obtain the pattern positions described above. This is accomplished using proportional changes listed on the "Summary of Machine Settings" calculated by the Design or Process Engineer. Although each job will vary due to the fact that the actual geometry is somewhat different, the following guide will serve as suggested starting values for the changes needed to affect the desired condition. Summary Proportional change description(s) - PHOENIX Fanuc 15MA Control systems Proportional Changes calculated on the "Summary" are First Order Changes. The values can be used in the full amount (100%) or in proportion as a percentage of the amount listed on the Summary (ie. 25%, 50%, etc.). There are four changes listed on the Summary and shown here in the order in which they appear. The PHOENIX Machine Proportional Change Designator for the MA Controller changes is 4.

CROSS CHANGE - 10 MINUTE - OFF HEEL OB, OFF TOE IB This is a change in the Spiral Angle to move the tooth contact pattern off the toe on one side and off the heel on the other. The change can be used to correct for or create "Cross" where necessary for heat treatment position. A 100% change as listed on the Summary will cause approximately a 0.015" (0.38mm) Cross in the Toe/Heel pattern positions as measured with the E (V) Axis in the test machine.

LAMNESS CHANGE - 10 MINUTE - TOP OFF OB, FLANK OUT IB This change is a modification to the actual Pressure Angle of the pinion member. The change will move the pattern off the top of the tooth on one side and out of the flank on the other. A 100% amount of this change will correct or cause approximately a 0.010" (0.25mm) lameness change as measured with the P (H) Axis in the test machine.

TOE/HEEL CHANGE - 10 MINUTE - OFF HEEL OB, OFF HEEL IB

This change will move the pattern off the toe or off the heel on both sides of the tooth. The change causes an increase in the Spiral Angle on one side of the tooth and a decrease on the other. With this change, a 50% amount will change the toe heel position of the pattern approximately 0.010" (0.25mm) off the toe or heel on both sides as measured with the E (V) axis position in the test machine.

Toe/Heel Patterns

Top/Flank Patterns

TOP/FLANK CHANGE - 10 MINUTE - TOP OFF OB, TOP OFF IB This change moves the pattern off the top or out of the flank on both sides of the tooth. The change is accomplished with an increase or decrease in the pressure angle on both sides of the tooth. A 0.001 Ratio of Roll Change results in approximately 0.0015" (0.04mm) topping or flanking as measured with the P (H) axis or pinion cone position in the test machine.

Summary Proportional change description(s) - PHOENIX Fanuc 15MB Control systems PHOENIX CNC Hypoid Generators manufactured with the Fanuc 15MB Control System allows the introduction of revised or improved proportional changes. These new style proportional changes are based upon the concept used in the GAGE/CMM programs for tooth form corrections. The changes are similar to the changes listed for the 15MA Control System machines, but utilize somewhat different values to accomplish the desired effect. The new style proportional changes are an option which is available when running the Summary of Machine Settings in the T2000 Computer Program. The PHOENIX Machine proportional change designator for the MB Controller changes is 30.

Lapping Face Hobbed gear sets Typically, Face Hobbed gear sets lap very quickly as compared to traditionally manufactured Bevel and Hypoid gears. Keeping in mind that lapping is intended as a refinement process, this is mainly due to the fact that the generating flats lie oblique to the lines of contact on the teeth. In addition, since the design normally results in some "Small Cutter Effect", the lapping will require taking this fact into account. Because of the fast lapping action, it is extremely important that the tooth contact pattern(s) are in the correct position after the heat treatment process and before lapping. It is very difficult to salvage lap these designs, and usually they will overlap before the desired change is made. During lapping the tooth contact pattern tends to move into the flank on both sides of the teeth, toward the toe on the drive side and toward the heel on the coast. The tooth contact patterns for hard, unlapped parts, should be near the final position favoring the center of the tooth on the drive, and slightly high favoring the toe on the coast. The lapper should be set up for very light brake load, the Toe-Heel Cams (SPC Lapper) should be set for 36 to 38 points (A good starting point would be for the Toe Cam at 20 and the Heel Cam at 18). The backlash should be set to 0.003" (0.076mm) and correctly maintained for the entire cycle. Normally, the time should be set to 20 Sec. per pass and 3 passes per side. This will result in a typical lapping cycle for an average Automotive hypoid gear set of 2 minutes. The following table lists recommended starting values for various Lapping Machines. Lapping Machine Settings for Face Hobbed Gear Sets

10

Machine No. 503 No. 514 No. 500 No. 506/507

Pinion Speed - RPM 1200 1800 1800 1800

Brake Load 35-40 (Dynamometric Brake Scale) 40 - 60 In.-Lbs. (4.5 - 6.8 Nm) 40 - 60 In.-Lbs. (4.5 - 6.8 Nm)

When using an E/P lapper, start with square moves to the toe and heel. Typically values of in the range of E/P = 15/15 will move the pattern to desired positions. The backlash should be maintained at 0.003 (0.076mm) as indicated above in the SPC lapper discussion. Typically the brake load on E/P lappers reads in actual torque and light load ie. 0 - 10 Ft. Lbs is recommended (0 - 13.6 Nm). ENDREM is a feature used to relieve the gear member tooth to reduce or eliminate lapping interference on the Drive Side Toe end of the teeth. In the Face Hobbing method ENDREM is accomplished by modifying the Cutter Blade Point Width and adjusting the Clearance Side Pressure Angle to cut a relief on the gear tooth. The desired effect is to accomplish a straight line cut-off 0.125 - 0.187 (3.1 - 4.7 mm) perpendicular to the gear root and face. Currently, the Summary Calculation program does not calculate values for the cutter specification to cut ENDREM. Therefore, the Engineer must calculate modified values for cutter manufacture. Generally, the values calculated are starting values and will be used to cut initial gear members with ENDREM. In the ENDREM development process, the first trial with the calculated blade specification will allow observation of amount and position of the ENDREM. It is normal to expect to make two or three iterations of modifications to the cutter specification to accomplish development of the desired ENDREM. If the amount of ENDREM is too small or too large on the tooth, the Blade Top Width (Point Width) should be increased or decreased, usually in increments of 0.005 to 0.010. If the Angle of the ENDREM is at a slope to the Root and Face, the Blade Angle of the Clearance Side of the Outside Blade (O.B.) should be increased or decreased, usually in increments of 2 Degrees. Many manufacturers have found it beneficial to make an initial gear tooth development without ENDREM. Then, the ENDREM is developed on a tooth form which has been confirmed to be correct for the application. An additional factor which should be considered at the time of design of the gear sets, is whether ENDREM is to be used on the application. In some cases, where the gear design is relatively large and the cutter diameter relatively small, the ability to use ENDREM can be reduced. Cutter Life Development In addition to the tooth contact pattern development, the development of cutter blade life is another important part of the Face Hob gear manufacturing method. The tool life is a function of many factors to include gear design, material specification and structure, cutting machine settings, coolant specification and application, and blade geometry. Relatively small changes in any of these factors could have a significant effect on cutter life. The computer programs used to calculate gear designs, cutter blade geometry, and cutting machine settings are continually updated to include the latest findings to maximize tool life. However, it is impossible to cover all possibilities and therefore it is necessary to review and often make small modifications by observation during the development of a gear job. Note that this tool life development can not be accomplished unless there are enough parts being cut to show significant wear on the cutting tools. In all cases listed below, the changes to be made are based upon observed wear on the cutter blades or deteriation of the tooth contact pattern. In addition, in some cases more than one of these changes may be necessary to gain the best cutter life. The typical cutter wear observed on the pinion cutting tools, is at the top of the tool on the clearance side of the blade (in the slot at or near the radius ). If the Outside Blade (Clearance Side) is wearing more than the Inside Blade (Clearance Side), change the Plunge Position found on the machine set-up Summary to a value more toward the toe end of the tooth (Increase the number on the Summary). If the I.B. is wearing more than the O.B., move the plunge position more toward the heel end of the tooth (Decrease the value). The machine setting to accomplish this is Item No. 50 - Start Roll Position. When changing this value in the summary, it is also necessary to change Item No. 60 - Feed Roll Position to the same value. Changes should be made in increments of 0.5 to 1.0 Degrees for the plunge position. An additional change which can be made on the pinion cutter to balance the life between O.B. and I.B. blades is to Step the Blades differently, or change the blade Height Above the Head in the cutter build. This change moves

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the blade which shows more wear down and the other blade up away from the head. When the O.B. (Clearance Side) shows more wear than the I.B., reduce the O.B. Blade Height Above Head (Dimension found in the cutter build specification on No. 300CG Blade Grinder Summary page), and increase the I.B. Blade Height Above Head dimension. This change should be made in increments of 0.003 (0.076mm) to 0.005 (0.127mm). Perhaps the largest gain in cutter life for the pinion member can be accomplished by increasing the Cutter Blade Top Width dimension. It is possible to increase this dimension by as much as 0.010 (.25mm) on some jobs. The increase in the Top Width should be made on the clearance side of the blade. To determine if an increase can be used on a specific job, it is necessary to make the change and then observe the effect on the part being cut. If the dimension is increased too much, the clearance side of the blade will cross over and cut an undercut or flat on the opposite side tooth surface. If this condition is seen, reduce the blade top width by enough to reduce or remove the cross over condition. The Cutter Blade Top Width is changed by increasing the value of the No. 300CG Summary Setting for Blade Top Width (with the latest version of the Computer Program this is item No. 18). When changing this value, it is also necessary to change the blade checking dimensions (No. 562 Blade Profile Device) to make the blade larger by the amount of increase in Blade Top Width. An additional change which can be made on the cutter blade is an increase in the Side Relief Angle on the clearance side of the blade. This change is made by increasing the value given as input for the No. 300CG Blade Profile Grinder and listed on the Summary. An increase of 1 to 3 Degrees in this value may help increase blade life. Coolant oil flow and direction is another factor which can significantly affect cutter life. It is important to have sufficient coolant flow of at least 25 gallons per minute. Increasing the coolant flow beyond this value is beneficial. In addition, the coolant must be in the proper location to flush chips from the cutter, and cool the blank and the cutter.

Recommended Control Procedure for Bevel & Hypoid Gears Manufactured by the Face Hobbing Method In Process Testing (Soft) Typically, special inspection is conducted on the first piece cut with a new cutter. In addition, an audit should be taken at some interval to assure that the operation is continuing to remain in control. It is recommended that in process Tooth Size Control be accomplished with a Dinging Ball type gage. This method is relatively inexpensive and easily accomplished by the operator of the cutting machine. Tooth size observation and control is especially important with Face Hobbing cutting method. A recommended Dinging Ball Tooth Size value of +/- 0.001 (Nominal Tolerance) has shown to be both practical and possible in the production environment. When changing a cutter, it is additionally important to verify that the tooth surface or Flank Form is acceptable. It is suggested that the gear member be controlled with a CMM Machine such as the Zeiss CMM with a Gleason GAGE Software Package. During the production run, however, it has been found to be acceptable to continue or start operation of the cutting machine based upon a Dinging Ball Size check, accompanied with a tooth contact pattern observation in a Bevel Gear Test Machine. The Gear can then be checked in the CMM to verify acceptable Flank Form configuration. Typically, if modifications are necessary they would be very minute and the parts made in the intrim period still within acceptable production limits. The Pinion Member is developed or modified to allow correct pattern position after the Heat Treatment operation This member could and/or may be checked with the CMM Machine, however, experience has shown that the observation of the Tooth Contact Pattern in a Bevel Gear Test Machine is a more accurate gage of the tooth configuration. Roll testing to verify the tooth contact pattern position should be performed

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on the first part after a cutter change. First Order Modifications, if necessary, should be made based upon the results of the roll test. Roll testing of either the Pinion or Gear should not take place unless the parts are cut to the correct size (Dinging Ball Check). The first piece after a cutter change should be inspected for Pitch Variation and Accumulated Pitch Variation with the CMM or other acceptable method. The parameter commonly identified as Runout is more correctly identified as Accumulated Pitch Variation in the gear measurement field. Typically, the quality requirements for Bevel and Hypoid gears are identified with AGMA tolerances based upon the size of the gear set to be manufactured. Typical Automotive gear sets are manufactured within AGMA Class 10 - 11. Example: 8 - 9 Pitch Diameter Ring Gear, 41 Teeth, 4.8 DP. For AGMA Class 10 - Runout Tolerance (Accumulated Pitch Variation) = 0.0017 For AGMA Class 11 - Runout Tolerance (Accumulated Pitch Variation) = 0.0014 In addition to a roll test for observation of the tooth contact pattern, control of the rolling motion characteristics may also be necessary for the best quality gear sets. Tooth Mesh Harmonics may vary somewhat from one part to another, however, careful control of the cutting and heat treatment process should result in a general trend. The soft part (microRadian) values should be the hard, unlapped desired value plus or minus the trend value. Hard Testing After Heat Treatment, Straightening, and process Turn or Grind, the Tooth Contact Pattern should be in the desired position. Normally, this is in the position on the tooth in which the final (Lapped) pattern should be so that excessive lapping is not necessary to force the pattern to the desired position. The Runout (Accumulated Pitch Variation) should be controlled within specified limits of AGMA values for the quality of the job to be manufactured. (Same as listed in the soft cutting above). Note: The Runout will not be reduced in the Lapping Process. The rolling motion characteristics (Tooth Mesh Harmonics) are significantly more important in the hard gear set than in the soft parts. If measuring the unlapped gear sets, values of 30 to 40 microRadians higher than final lapped gear set for the First Harmonic of gear mesh are typical. After Lapping the Tooth Contact Pattern should be in the desired position, with the desired shape and length. With a process which is totally in control an audit should suffice. However, in most gear manufacturing facilities a 100% test of the tooth contact pattern to select and/or verify the Pinion Cone Assembly position is more realistic. Runout (Accumulated Pitch Variation) should be controlled within limits of AGMA values for the quality of the job to be manufactured. (Same as listed in the soft cutting above) . Note: The Runout will not be reduced in the Lapping Process. Acceptable rolling motion characteristics (Tooth Mesh Harmonics) will vary with each application, development and manufacturer. Acceptable limits of 20 to 40 microRadians for the First Harmonic of gear mesh are typical within the Passenger Car/Light Truck Automotive Industry. These values are for actual running position at light test loads. Other test procedures, such as placing a limit at values at plus or minus given Pinion Cone or Backlash settings may increase the acceptability limit(s).

References: The Application of the Face Milling and Face Hobbing Processes on the Gleason Phoenix Universal Generators by Robert G. Hotchkiss - Gear Technology, The Gleason Works ETI 3494/January 1990

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Design and Manufacture of Face Hobbed Bevel and Hypoid Gears by Robert G. Hotchkiss Director - Gear Technology, The Gleason Works 21791/ETI3500A TRI-AC Cutter System - The Gleason Works The Theory of Modern Bevel Gear manufacturing by Robert G. Hotchkiss Director - Gear Technology, The Gleason Works ETI4205/3-89 State of the Art Technology for Processing Bevel and Hypoid Gears by John V. Thomas Manager - Gear Technology, The Gleason Works ETI3495 FHPAPERA.DOC L. S. Pitts 06/03/97

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