Gear Tooth Tip Processing After High-Hardness Shot Peening
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Solution Overview
Problem
The existing shot peening method for manufacturing gears, which uses relatively low hardness shot particles, requires multiple steps and is time-consuming, as it necessitates preliminary peening to prevent projection deformation on the tooth tip, thereby prolonging the gear manufacturing process.
Innovation Solution
A method that involves shot peening with higher hardness shot particles, followed by heating the tooth tip using a high-frequency induction heating apparatus to soften the projection, and then rotationally driving the gear to deform the projection to conform to another gear's tooth surface, eliminating the need for preliminary peening and reducing processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shot peening is performed using shot particles having relatively low hardness to prevent projection deformation on the tooth tip, then the tooth surface can be hardened without forming projections, but the processing time becomes excessively long due to requiring at least three shots
Solution Approach 1:
The invention applies preliminary action by performing a first preliminary shot peening on the tooth tip before the main shot peening process. This preliminary treatment prepares the tooth tip surface to withstand the subsequent main shot peening without forming projections, allowing the use of higher hardness shot particles in the main process while maintaining surface quality and reducing total processing time.
2Manufacturing precision
If multiple types of shot peening are performed to harden the tooth surface and prevent projection formation, then the gear quality is improved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The invention segments the shot peening process into distinct stages: a first preliminary shot peening on the tooth tip using lower hardness particles, followed by a main shot peening on the entire tooth surface using higher hardness particles. This segmentation allows each stage to be optimized independently, achieving high surface quality without requiring excessive processing steps.
Solution Approach 2:
The invention applies local quality by using different shot particle hardness levels for different regions of the gear. The tooth tip receives preliminary treatment with lower hardness particles to prevent projection formation, while the main tooth surface undergoes shot peening with higher hardness particles for maximum hardening effect. This localized approach optimizes both surface quality and processing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient processing of projections on gear tooth tips using high hardness shot peening, shortening manufacturing time by reducing the number of peening steps, while ensuring accurate assembly and preventing trochoid interference, thus simplifying the manufacturing process.
Implementation Method 1
heating the tooth tip using a high-frequency induction heating apparatus to soften the projection
Implementation Method 2
performing shot peening in which shot particles are jetted onto a tooth surface of a gear base material, the tooth surface while applying residual stress to the tooth surface
Data Source
AI summary
The present disclosure provides a method for manufacturing a gear capable of processing a projection formed on a tooth tip by shot peening while reducing time for manufacturing the gear. A method for manufacturing a gear includes: a process of hardening, by performing shot peening in which shot particles are jetted onto a tooth surface 1a of a gear base material, the tooth surface while applying residual stress to the tooth surface; a process of softening, by at least heating a tooth tip of the gear base material having the hardened tooth surface, the tooth tip; and a process of rotationally driving the gear base material having the softened tooth tip by engaging it with another gear.