1. Tractor front shaft ① Axle Housing ② Connect Case ③ Connect Arm1 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

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

3. Bevel Cutting FACE MILLING HARDAC cutter NC machining Low productivity
Bevel Cutting (40s)
3-axis Machining (12s)

4. 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.

5. Broach
The broach is run linearly against a surface of the workpiece to effect the cut.
BROACH CUTTER
Gear Broach

6. 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

7. 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

8. Inspection
Standard Contact Area
Contact Area Inspection

9. Bebel Gear Forging Gear design Forging simulation Die Machining
Inspection

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

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

12. Forging
Closed forging die
Press machine

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

14. Reference Gleason: www.gleason.com 세일공업: www.seilkorea.com (정영석, 박창섭)
KMC: (김홍철)
AFDEX: (전만수)