Operator Precision Gear Grinding Course

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Operator Precision Gear Grinding CourseINSTRUCTOR:Terry KlavesEmail: terryklaves@gmail.comCOURSE INFORMATIONCourse DescriptionExplore gear grinding processes, machine kinematics and setup, pitfalls, failures and expectationsrelated to finish ground gearing. Learn definitions of gearing component features, process steps fromblanking, through heat treatment to finished part ready to ship. Study aspects of Quality Assurance,Inspection Documentation and corrective actions for measured non-conformances. Understand preheat treat, heat treatment and post heat treatment operations including the how’s and why’s toproduce finished gears that conform and perform to end user expectations.It is recommended that you spend a minimum of 1 hour reading and reviewing the material each day.Who Should AttendThis course would be of interest to both entry and high level gear grind operators, inspectors and qualityassurance people who need to better understand why and how gear designs are optimized and how towork with non-standard gear geometry. The course would also benefit pre-finishing operators byunderstanding part datum control and subsequent gear finishing processes. Participants can also gaininsight on how improper finishing techniques can contribute to pre-mature gear failures. Entry levelgear designers, process and manufacturing engineers can develop a basic understanding of gearfinishing cycles, cycle times and cost. Gear manufacturing project managers and production managerscan develop a better understanding of time required to setup and finish high performance gearsets thatwill meet or exceeds application expectations.Learning Objectives Review and challenge control of part datums for pre-heat treatment operations, use datum’sconsistently through finishing operations given part prints Anticipate and correct for part distortion during heat treatment knowing the actual heattreatment process used. Understand gear grinding kinematics for both form and generating machines along withallowable metal removal rates and wheel dressing intervals based on type of grinding wheelsbeing used Ask questions of gear designers and manufacturing engineers to acquire all information requiredto produce conforming finished gears Accurately apply and inspect pre-calculated micro-geometry modifications derived fromcomplex contact analysis software Perform component finishing machine setup, alignments, component inspection andcalibrations to established ISO standards with hands on lab if available, or, run calculations ongrinding cycle times based on various target accuracies and grinding techniques Select the optimum grinding wheel specification given part print and heat treatment used1

Achieve compliance with finished parts to meet print requirements and customer performanceexpectationsAccurately measure pre and post finish gear tooth thickness given finished tooth thicknessspecificationsAvoid and detect the presence of Twist ErrorAvoid and detect presence of grind burn temperAvoid typical gear fatigue failure modes resulting from improper finishingIdentify common non-conformances, apply problem solving techniques and corrective actionsRequired Textbooks (Provided by AGMA)Operator Precision Gear Grinding manual by Terry Klaves.COURSE OUTLINEDay One Why Finish Case Hardened Gears Correct for growth and distortion that occurs during heat treatment Improve finished accuracy to take full advantage of high strength, case hardenedmaterial Introduction to gear tooth fatigue loading Introduction to applied load, torque, speed, horsepower Definition of gear geometry Gear accuracy Allowable bending and contact fatigue stresses for various materials Finishing Options – Case Hardened Gears Form Grind – kinematics and advantages Generating Grind – kinematics and advantages Skive Hone Gash Five Axis Machining Print Data and Finished Requirements Part datums Part geometry Example of gear manufacturing summary Micro-geometry Target Production Accuracy Target accuracies for various processes in A and Q values Active and obsolete gear accuracy standards Gear Finishing Process Steps Consistent control of part datums Gear tooth roughing and stock allowance Gear tooth size measurement Predict dimensional changes during heat treatment Special processes to be considered – shot peen, isotropic finishing, black oxide coating Finish Grinding Machine Setup Required machine data input2

Machine axis alignment Work holding tooling Grinding wheel selection, Qw, Vw Wheel dressing parameters Limitations of on-board inspectionGrinding Wheel 101 Grinding wheel definitions and descriptions Dressable and Non-dressable grinding wheels Tool wearHands on Lab or Gear Grinding Simulator Hands on lab grinding gears if facility is available Run actual gear grinding simulator software to calculate grinding cycle times for a givenpart and various target accuracies, surface finishes and grinding processesInternal/External Gearing Basics Target performance parameters, spur vs. helical Twist error Tooth helix Tooth profile Tooth spacing Inspection per ISO and AGMA accuracy standardsGear Geometry Optimization for Maximum Power Density Profile shift Non standard addendums High contact ratio Asymmetric gear teeth Tuning a gearset for performance Tooth contact analysis Twist errorGrowth During Heat Treatment Backlash Tooth size measurement tools and techniquesTooth Surface Finish Micro-pitting Macro-pittingAdditional Gear Specifications Surface Hardness Case Depth Core HardnessDay Two Grind Burn and Temper Grind burn/temper White burn Inspection for grind burn – nital etch – ISO 14104 Barkhausen Gear Rating and Failures Related to Improper Finishing3

Tooth bending fatigue from grind steps Macro-pitting from grind burn/temper Micro-pitting from reduced contact area Trouble Shooting Finish Grinding Accuracy of helix Accuracy of profile Accuracy of spacing Limitations of onboard inspection Machine setup/alignment and related gear accuracy issues Terry Klaves gear grinding troubleshooting guide Summary, Review and DiscussionSTUDENT FEEDBACK AND GRADING PROCEDURESAssignmentsAssignments and learning activities are given and directed at the discretion of the instructor.COURSE MANAGEMENTWeather Delays and CancelationsWe will communicate any cancellations, delays or other concerns for safety prior to class via email,voicemail, and/or text message. Please be sure that we have all pertinent contact information as youtravel to your class location.Attendance for Domestic and International StudentsPlease be mindful that these are short, accelerated courses. Attendance is extremely important. If youare going to be absent from any class day, please contact the course coordinator. Rosemarie Bundoc,Education Manager, bundoc@agma.org or Stephanie Smialek, Education Coordinator,smialek@agma.orgPlagiarism, Cheating and other types of MisconductPlagiarism 1, cheating and other types of misconduct are unacceptable.Students with DisabilitiesStudents requiring assistance and accommodation should complete the Special AccommodationRequest form and submit it to Stephanie Smialek, Education Coordinator, at smialek@agma.org. She canbe reached at 703-838-0069.Grievance ProceduresStudents who have concerns about the class are encouraged to contact Stephanie Smialek, EducationCoordinator, at smialek@agma.org or 703-838-0069.Outline ChangesThe instructor reserves the right to modify the outline during the course of the class.Plagiarism is defined as “the use or close imitation of the language and thoughts of another author and therepresentation of them as one’s own original work.”14

LEARNING AND OTHER RESOURCESLinks for writing resources: .comLinks for Math resources: www.sosmath.com Khan Academy on www.youtube.comLinks for time management, study skills and note taking resources: www.mindtools.comwww.testakingtips.comLinks for career resources: https://www.agma.org/newsroom/jobs/Industry News: https://www.agma.org/newsroom/industry-news/5

Grinding wheel selection, Qw, Vw Wheel dressing parameters Limitations of on-board inspection Grinding Wheel 101 Grinding wheel definitions and descriptions Dressable and Non-dressable grinding wheels Tool wear Hands on Lab or Gear Grinding Simul

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