Tractor front shaft ① Axle Housing ② Connect Case ③ Connect Arm 1 2 3 4 5 6 7 8 9 10 ① Axle Housing ② Connect Case ③ Connect Arm ④ Gear Case ⑤ Gear Housing ⑥ Drive Differential Comp ⑦ 1st Bevel Gear ⑧ Final Bevel Gear ⑨ Final Pinion Gear ⑩ Wheel Shaft

Bevel Gear Process Pinion Gear Bevel Gear Forging Turning Straight Bevel Broaching Carburizing Grinding Bevel Gear Forging Turning Straight Bevel Broaching Carburizing

Bevel Cutting FACE MILLING HARDAC cutter NC machining Low productivity http://www.youtube.com/watch?v=8pXtSWIJ7Ac Bevel Cutting (40s) http://www.youtube.com/watch?v=fOLaJMh6DXQ 3-axis Machining (12s)

Gear Lapping Liquid abrasive compound is feed into the rotating gear pairs to smooth teeth surfaces. Gear lapping is the process of imparting a very fine finish and high degree of accuracy to gear teeth. Lapping typically improves the wear properties of gear teeth. To ensure smooth and quiet running, the Gears and Pinions are lapped after hardening. Lapping is accomplished by running mating pairs together in a gear lapping machine and feeding a liquid abrasive compound under pressure into the gear pair. The compound removes small amounts of metal as the gears rotate, thus refining the tooth surface and achieve desired contact pattern. One of the most common applications for gear lapping many are familiar with is the process of diff lapping. Diff lapping is the lapping of the gear teeth in a vehicles differential to improve gear life and increase strength by removing minor surface imperfections from the tooth profile.

Broach The broach is run linearly against a surface of the workpiece to effect the cut. BROACH CUTTER http://www.youtube.com/watch?v=2K45B6tDqsg Gear Broach

Accumulative Pitch Error Inspection ITEMS SPEC. (JIS 4) DATA (LH/RH) RESULT Pitch Variation 56 46/42 O.K Pitch Error 73 68/61 Accumulative Pitch Error 230 101/106 Run-out 100 77

Accumulative Pitch Error Inspection ITEMS SPEC. (JIS 4) DATA (LH/RH) RESULT Pitch Variation 62 23/27 O.K Pitch Error 81 39/45 Accumulative Pitch Error 250 157/194 Run-out 200 165

Inspection Standard Contact Area Contact Area Inspection

Bebel Gear Forging Gear design Forging simulation Die Machining Inspection http://www.afdex.com

Forging simulation <12T Bevel gear> <20T Bevel gear>

Die machining <12T Bevel gear> <20T Bevel gear>

Forging Closed forging die Press machine

Forged bevel gear <12T Bevel gear> <20T Bevel gear>

Reference Gleason: www.gleason.com 세일공업: www.seilkorea.com (정영석, 박창섭) KMC: www.kmce.co.kr (김홍철) AFDEX: http://www.afdex.com (전만수)