In industrial applications, the failure of a gear shaft can lead to significant operational disruptions and safety concerns. This analysis focuses on the cracking observed in a 17CrNiMo6 steel gear shaft after undergoing a series of heat treatments and grinding processes. The gear shaft was subjected to normalizing, carburizing, quenching, cold treatment, and low-temperature tempering,… Read more: Analysis of Gear Shaft Cracking

In the field of aviation, the Auxiliary Power Unit (APU) plays a critical role in providing independent compressed air, electrical power, and emergency energy to enhance flight safety. The worm gear mechanism used in APU air passage hatch cover actuators is a core component characterized by its compact size and high load-bearing capacity. Ensuring the… Read more: Parametric Modeling and Simulation Analysis of Worm Gear for Aviation APU

In mechanical engineering, worm gears are widely used for their high transmission ratios, smooth operation, and low noise characteristics. However, failures such as bending deformation in worm shafts are relatively rare but critical. In this analysis, I investigate a case where a worm gear lifting mechanism experienced seizure due to adhesive wear, leading to bending… Read more: Failure Analysis of Worm Gear Lifting Mechanism

This research addresses the critical challenges in power transmission under extreme geometric constraints through systematic investigation of hypoid gears with small shaft angles. The study focuses on three core aspects: geometric parameter design, meshing behavior control, and precision manufacturing technology. 1. Geometric Parameter Design Methodology The spatial pitch cone contact mechanism forms the theoretical foundation… Read more: Research on Geometric Design and Meshing Characteristics of Hypoid Gears with Small Shaft Angles

This study investigates the lubrication characteristics and stress distribution of spiral bevel gears under transient operating conditions. By combining finite element analysis with elastohydrodynamic lubrication theory, the research establishes a computational framework to evaluate oil film thickness variations and lubrication states during gear meshing. 1. Transient Stress Analysis 1.1 Gear Parameters and Material The spiral… Read more: Simulation Research and Analysis of Spiral Bevel Gear Lubrication

Abstract:In the process of internal meshing power gear honing, elastic-plastic deformation occurs near the contact area between the workpiece gear and the honing wheel. This deformation is the superposition of various factors, and residual stress is generated on the workpiece surface after processing. The generated residual stress significantly affects the gear’s performance, fatigue strength, dimensional… Read more: Residual Stress on the Surface of Workpieces in Internal Meshing Power Gear Honing

In the field of precision transmission systems, hypoid gears have emerged as a critical component due to their ability to transmit power between non-parallel shafts with high efficiency and compact design. Following harmonic drives and RV reducers, hypoid gear reducers represent a novel transmission form for robotic applications, offering advantages such as high stiffness, high… Read more: Active Tooth Surface Design and Performance Optimization of High Reduction Ratio Hypoid Gears

In aeronautical transmission systems, bevel gears play a critical role in transferring power between non-parallel shafts. Among these, straight bevel gears and zero bevel gears are often considered interchangeable due to their kinematic similarities, particularly in applications requiring bidirectional operation and minimal axial thrust. However, fundamental differences in tooth geometry lead to significant variations in… Read more: Comparative Analysis of Transmission Error in Straight Bevel Gears and Zero Bevel Gears

The meshing quality of helical gears in automotive transmissions is critically influenced by support stiffness and surface treatment. This study investigates the combined effects of shaft support stiffness variations and manganese phosphate conversion coatings on gear meshing characteristics through numerical simulations and experimental validation. 1. Theoretical Analysis of Meshing Characteristics For helical gear pairs in… Read more: Influence of Support Stiffness and Tooth Surface Coating on Meshing Characteristics of Helical Gear Pair

Surface integrity governs the contact fatigue performance of gears, where microscopic imperfections trigger catastrophic gear failure. To quantify surface integrity’s impact, we characterize 18CrNiMo7-6 and 16Cr3NiWMoVNbE carburized gears under grinding, shot peening, dual shot peening, and barrel finishing. Contact fatigue testing reveals dual shot peening elevates subsurface compressive stress to 1250 MPa and surface hardness… Read more: Research on Contact Fatigue Limit Prediction Method of Carburized Gears Based on CatBoost Algorithm

In our manufacturing facility, we encountered significant challenges with imported gear grinding machines, particularly those used for precision gear profile grinding. These machines, essential for achieving high tolerances in gear production, often suffered from issues like grinding cracks and surface burns due to inadequate cooling during the gear grinding process. As a maintenance and engineering… Read more: Automatic Coolant Control System for High-Precision Gear Grinding

In modern mechanical transmission systems, spur gears play a critical role in parallel-axis power transmission due to their simplicity and efficiency. However, traditional involute spur gears exhibit inherent sliding between tooth surfaces, leading to friction, wear, and noise. To address these issues, we propose a novel design for pure rolling spur gears with a circular… Read more: Design of Pure Rolling Spur Gears with Circular Arc Tooth Profile

Central drive gear hubs are critical components in bulldozer power transmission systems. Failure causes complete loss of mobility and steering capability, with fracture being the predominant failure mode. This article presents a comprehensive analysis of gear hub fractures through material science, structural mechanics, and advanced gear technology investigations. Working Principle and Transmission Path Power transmission… Read more: Analysis and Optimization of Central Drive Gear Hub Failure in Bulldozers

In mechanical transmission systems, spur gears are widely used due to their simplicity and efficiency. The mesh stiffness of spur gears is a critical parameter that influences dynamic behavior, vibration, and noise. Time-varying mesh stiffness (TVMS) arises from the alternating single and double tooth contact during gear operation. Various factors, such as tooth profile modifications,… Read more: Influence of Tooth Surface Friction and Geometric Eccentricity on Mesh Stiffness of Profile-Shifted Spur Gears

In this study, we investigate the bending strength of large modulus rack and pinion gear systems under uniform wear conditions, with a focus on applications such as ship lifts and heavy lifting platforms. The rack and pinion gear mechanism is widely used in industrial machinery due to its ability to convert rotational motion into linear… Read more: Analysis of Bending Strength in Large Modulus Rack and Pinion Gear under Uniform Wear

As an engineer specializing in mechanical transmission systems, I have dedicated years to refining the manufacturing processes for gear shafts, which are critical components in various applications, including automotive and industrial machinery. The gear shaft plays a pivotal role in transmitting torque and reducing rotational speed, particularly in modern systems like electric vehicles where efficiency… Read more: Optimization of Gear Shaft External Tooth Processing Device and Process Validation

In mechanical transmission systems, straight bevel gears play a critical role in transferring motion and power between intersecting shafts. However, excessive friction power losses during meshing can lead to reduced efficiency, thermal deformation, and even gear failure, especially under inadequate lubrication. Accurately predicting the meshing efficiency of straight bevel gears is essential for optimizing design… Read more: Comprehensive Analysis of Meshing Efficiency in Straight Bevel Gears Under Complex Lubrication Conditions

In the automotive industry, the transmission system plays a critical role, and the gear shaft is a key component that demands high precision in manufacturing. As an engineer involved in machining processes, I have encountered numerous challenges in turning gear shafts for transmissions. This article details my firsthand experience in analyzing and resolving issues related… Read more: Analysis and Solution for Turning Automotive Gear Shafts

As an internal gear manufacturer, I have encountered numerous challenges in producing high-precision components for aerospace applications. Internal gears made from 9Cr18 martensitic stainless steel are critical in drive mechanisms due to their excellent wear resistance and hardness. However, cracking issues during processing can lead to significant reliability concerns. In this analysis, I will delve… Read more: Failure Analysis of Cracks in High-Strength Martensitic Stainless Steel Internal Gears

The strength and lifespan of automotive gears critically influence the performance and reliability of vehicles. Approximately 74% of gear transmission failures originate from surface fatigue, highlighting the necessity for advanced surface engineering solutions. This article examines cutting-edge surface strengthening methodologies that enhance fatigue resistance, durability, and tribological performance in high-stress automotive gear applications. Automotive Gear… Read more: Research Status and Development Trends of Surface Strengthening Technologies for High-Strength Automotive Gears

In modern manufacturing, gear hobbing is a highly efficient process for producing both conventional and non-circular gears. The gear hobbing machine plays a critical role in achieving precision in gear profiles. However, factors such as guideway straightness errors, ball screw backlash, tool wear, and thermal deformation can introduce significant errors in gear contour accuracy. Non-circular… Read more: Optimization of PID Control for Non-Circular Gear Hobbing Machine Tracking Error Using Particle Swarm Algorithm

In my research, I focus on the modeling and analysis of contact stress in helical gears used in heavy vehicle transmissions. Helical gears are widely employed in mechanical transmission systems due to their high efficiency, smooth operation, and ability to handle high loads. However, issues such as pitting and fatigue failure caused by stress concentration… Read more: Modeling and Analysis of Contact Stress in Helical Gears for Heavy Vehicle Transmissions

In the field of mechanical engineering, straight bevel gear systems are widely employed in various applications such as automotive transmissions, aerospace mechanisms, and industrial machinery due to their ability to transmit power between intersecting shafts. However, the presence of backlash and time-varying parameters in these systems introduces nonlinear vibrations that can lead to dynamic instabilities,… Read more: Parametric Solution Domain Structures for Bifurcation and Non-Meshing Dynamics in Straight Bevel Gear Systems

In modern mechanical transmission systems, spur gears play a critical role due to their simplicity and efficiency in power transfer. However, issues such as transmission errors, noise, and vibration often arise during operation, leading to reduced performance and lifespan. This study focuses on optimizing the helix modification of spur gears using a multi-objective regression equation… Read more: Optimization of Spur Gear Helix Modification Based on Multi-Objective Regression Equation

In modern manufacturing, CNC machine tools play a critical role as the “mother machines” of industry, providing essential equipment for mechanical processing. The protective door is a vital safety component that shields operators from hazards like flying chips and cutting fluids. However, many existing protective doors rely on manual operation, leading to issues such as… Read more: Design of Electric Push Rod Type Protective Door for CNC Machine Tools Based on Bevel Gear Structure

Electric vehicles (EVs) face unique NVH challenges due to the absence of engine masking effects. Gear whine in reducers becomes particularly noticeable, originating from transmission error (TE) during gear meshing. This high-frequency noise occurs at the gear meshing frequency: $$ f = \frac{N \times n}{60} $$ where \( f \) represents meshing frequency (Hz), \(… Read more: Analysis and Optimization of Transmission Error in Electric Vehicle Gear Reducers

Spiral bevel gears are critical components in automotive rear axle systems, where coupled vertical vibrations often lead to uneven wear patterns. This paper presents a novel detection method combining Delaunay triangulation with Hermite interpolation-based Local Mean Decomposition (LMD) to address wear quantification challenges. The proposed approach achieves 98.7% detection accuracy through advanced surface modeling and… Read more: Wear Detection of Automotive Spiral Bevel Gears Based on Delaunay Triangulation

In industrial applications, gear reducers play a critical role in transmitting power and motion, with internal gears being a key component in many high-torque systems. As an internal gear manufacturer, we often face challenges in ensuring the precision and efficiency of internal gears under heavy loads. Traditional testing methods for internal gears are costly and… Read more: Virtual Performance Testing System for Internal Translation Gear Reducer

This paper establishes a dynamic model for spur gear systems considering energy dissipation during tooth back collisions. The time-varying meshing stiffness is formulated as: $$ k_m(t) = \begin{cases} k_{\text{intact}} \cdot \alpha(t) & \text{Healthy teeth} \\ k_{\text{broken}} \cdot \beta(t) & \text{Partially broken teeth} \end{cases} $$ where $\alpha(t)$ and $\beta(t)$ represent load distribution coefficients for healthy and… Read more: Nonlinear Vibration Characteristics of Spur Gear Systems with Partial Tooth Breakage Under Meshing-Collision Interactions

Involute spur cylindrical gears are widely used in mechanical transmission systems due to their high load-bearing capacity, efficiency, and cost-effectiveness. However, during long-term service, friction and wear on the tooth surfaces can lead to reduced transmission accuracy and efficiency. To address this, tooth profile modification, such as drum-shaped crowning, is often applied to restore the… Read more: Research on Drum Shaped Tooth Profile Modification and Fatigue Lifetime of Parallel Axis Involute Spur Cylindrical Gears

In my extensive experience working in factory workshops, I have encountered numerous challenges related to gear manufacturing, particularly when dealing with carburized and quenched hardened gears. Carburizing is a critical heat treatment process that involves diffusing active carbon atoms into the surface of metal workpieces by heating them in a chemical medium rich in carbon.… Read more: Research on Gear Grinding Allowance for Carburized and Quenched Hardened Gears

In my extensive experience working with industrial machinery, particularly in marine environments such as offshore oil platforms, I have encountered numerous instances where worm gear driven butterfly valves exhibit significant operational difficulties, especially when it comes to opening and closing. These valves, which utilize worm gears for motion transmission, are prized for their compact design,… Read more: Maintenance and Repair of Worm Gear Driven Butterfly Valves

With the rapid expansion of urban areas and increasing reliance on public transportation, subway systems have become a critical component of urban mobility. The safety and reliability of subway vehicles are paramount, and the transmission system, particularly the helical gears within the gearbox, plays a vital role in ensuring smooth operation. Helical gears are widely… Read more: Prediction and Optimization of Bending Fatigue Life of Helical Gears for Subway Vehicle Transmission

In the field of mechanical transmission systems, worm gear reducers play a critical role due to their compact design, high reduction ratios, and smooth operation. They are widely employed in aerospace, agricultural machinery, and automation equipment. However, enhancing the load capacity of a worm gear reducer without altering its external dimensions or material composition presents… Read more: Optimization Design of Worm Gear Reducer Load Capacity Based on ANSYS

In the realm of high-precision gear shaft production, particularly for components like harmonic reducers, achieving consistent accuracy in mass manufacturing is paramount. As an engineer specializing in fixture design, I have developed a specialized eccentric gear shaft fixture that addresses the challenges of maintaining stability in machining conditions, even with minor environmental fluctuations. This gear… Read more: Eccentric Gear Shaft Fixture Design for High-Precision Manufacturing

In the field of mechanical power transmission, straight bevel gears play a critical role in transferring motion and torque between intersecting shafts. However, the performance of these gears is highly susceptible to installation errors, which arise from assembly inaccuracies, manufacturing tolerances, and measurement tool limitations. These errors can lead to undesirable effects such as noise,… Read more: Sensitivity Analysis of Installation Errors in Modified Tooth Surfaces of Straight Bevel Gears

As a researcher in metal forming technologies, I have extensively studied the challenges faced by internal gear manufacturers in producing high-quality internal gears efficiently. Internal gears are pivotal components in transmission systems like automotive gearboxes and planetary reducers, where precision and durability are paramount. Traditional machining methods, such as cutting, often lead to high production… Read more: Precision Forming of Internal Gears with Expansion Die Cavity: An In-Depth Analysis

In this article, I will describe the parametric modeling process for a zero bevel gear with equal top clearance using Siemens NX 6.0 software. The zero bevel gear is characterized by a reference point spiral angle β = 0, which results in minimal axial forces during operation. This makes it an ideal replacement for straight… Read more: Parametric Modeling of Zero Bevel Gear with Equal Top Clearance in NX 6.0

In the field of fluid power transmission, helical gears have gained significant attention due to their ability to provide smooth operation, high efficiency, and reduced noise compared to traditional gear designs. The double arc helical gear pump, in particular, offers advantages such as large flow capacity, lightweight structure, and insensitivity to fluid contaminants, making it… Read more: Mechanical Characteristics of Double Arc Helical Gear Pump Rotor under Fluid-Structure Coupling

Rack and pinion gear systems are widely used in various mechanical applications, such as railway systems and lifting platforms, due to their ability to convert rotational motion into linear motion. The time-varying mesh stiffness of a rack and pinion gear pair is a critical factor influencing the dynamic behavior, vibration, and noise levels of the… Read more: Analytical Calculation of Time-Varying Mesh Stiffness in Rack and Pinion Gears

This study investigates the steady-state temperature distribution and thermal deformation characteristics of helical gears in electric drive systems. A parametric finite element model is developed using APDL to analyze heat generation mechanisms and deformation patterns under operational conditions. The research emphasizes the critical role of helical gear geometry in thermal management and mechanical stability. Thermal… Read more: Steady-State Temperature Field and Thermal Deformation Analysis of Electric Drive Helical Gears

In my extensive experience with mechanical component failure analysis, I have encountered numerous cases where surface defects in gear shaft elements lead to operational failures. This article presents a comprehensive investigation into the formation of hair cracks on gear shaft surfaces, particularly focusing on 45 steel components used in power transmission systems. The gear shaft… Read more: Investigation of Hair Crack Formation Mechanisms in Gear Shaft Components

Abstract: Gear manufacturing constitutes the largest industry among mechanical basic parts. With the rapid development of equipment manufacturing in China, the requirements for gear processing have become increasingly stringent. The continuous application of advanced CNC equipment has significantly transformed cutting processes and technologies. Gear shaving, as a core part of the gear finishing process, is now… Read more: Research on Efficient Gear Shaving Process and Environmental Protection Cutting Fluid

In modern automotive engineering, hypoid gears are widely used in rear axle drive systems due to their high mechanical efficiency, strong load-bearing capacity, low noise, and smooth transmission. However, under complex operating conditions such as high speed and heavy load, hypoid gears often experience contact fatigue failure, which significantly affects the reliability and service life… Read more: High-Cycle Fatigue Life Assessment of Hypoid Gears Based on Load Spectrum

In industrial applications, straight bevel gears are crucial components for transmitting motion and power between intersecting shafts, typically at a 90-degree angle. Their simplicity in design, manufacturing, and installation makes them widely used in various machinery. However, machining large-diameter straight bevel gears poses significant challenges, especially when specialized gear-cutting equipment is unavailable. Many enterprises lack… Read more: Machining Straight Bevel Gears on CNC Horizontal Boring Mills

Spur gears are critical components in power transmission systems, widely used in automotive, high-speed rail, and aerospace industries due to their efficiency and reliability. Traditional manufacturing methods, such as hobbing and shaping, often result in low material utilization, discontinuous flow lines, and high production costs. In contrast, extrusion forming offers a promising alternative by enabling… Read more: Optimization of Spur Gear Extrusion Forming Process Parameters Using PCA and GRA

In the field of mechanical transmission, straight bevel gears play a critical role due to their ability to transmit motion between intersecting shafts. As a researcher focused on advanced manufacturing processes, I have extensively studied the hot-cold compound forming technique for producing high-quality straight bevel gears. This method combines the advantages of hot forging, such… Read more: Optimization Design of Pre-forging Tooth Profile for Straight Bevel Gears

This study presents a systematic approach for hypoid gear modification and NVH performance optimization in automotive drive axles. The methodology combines numerical modeling, finite element analysis, and experimental validation to address gear meshing noise issues caused by load-induced misalignment. 1. Numerical Tooth Surface Generation The mathematical model for hypoid gear grinding using the HFT method… Read more: Tooth Surface Modification and NVH Performance Optimization of Hypoid Gear for Automotive Drive Axle

In the automotive industry, the drive axle assembly plays a critical role in power transmission, and the spiral bevel gear set is a core component. The gear shaft, particularly its threaded section, is essential for securing connections and transmitting torque. However, during the assembly of a rear axle drive system, we encountered multiple instances of… Read more: Analysis and Improvement of Gear Shaft Thread Fracture

In modern mechanical transmission systems, helical gears play a critical role due to their ability to transmit power smoothly and efficiently between non-parallel shafts. Non-orthogonal helical gears, which operate with intersecting axes at angles other than 90 degrees, are particularly valuable in applications such as automotive differentials, helicopter reducers, robotics, and conveyor drives. These gears… Read more: Mathematical Model and Contact Characteristics of Non-Orthogonal Helical Gear Systems

As an engineer specializing in gear design, I have always been fascinated by the complexities of internal gear systems and their applications in various mechanical transmissions. Internal gears play a critical role in power transmission systems, offering advantages such as compact design, high efficiency, and reduced sliding losses compared to external gears. In this article,… Read more: Analysis of Tooth Root Profile Modification and Meshing Characteristics in High-Contact-Ratio Internal Gears

In modern automotive transmission systems, the demand for high-precision gear components has led to the widespread adoption of back taper teeth structures. Among these, flat root back taper gears present unique challenges in manufacturing due to their constant root diameter and varying tooth thickness along the gear width. This paper delves into the program debugging… Read more: Hobbing Flat Root Back Taper Gears

Spur gears are fundamental components in mechanical transmission systems, widely used in industries such as aerospace, automotive, and manufacturing. However, gear failures like cracks and pitting can lead to significant performance degradation, increased noise, and even catastrophic system failures. Traditional experimental methods for simulating different failure types and degrees in spur gears are often costly… Read more: Dynamic Modeling, Modification, and Experimental Verification of Spur Gears with Faults

In the field of power transmission systems, bevel gears play a critical role in transferring motion and torque between intersecting shafts. Among various types, straight bevel gears are widely used in automotive, aerospace, and industrial applications due to their simplicity and ease of manufacturing. However, traditional manufacturing methods for straight bevel gears, such as forging… Read more: Optimization of Meshing Performance for Straight Bevel Gears Machined by Dual Interlocking Circular Cutters

This study investigates the meshing stiffness calculation of spiral bevel gears using finite element analysis (FEA), focusing on the dynamic behavior influenced by time-varying stiffness. The methodology addresses limitations in existing approaches that approximate stiffness curves with trigonometric functions, which compromise accuracy in dynamic simulations. 1. Mathematical Formulation of Meshing Stiffness The single-tooth meshing stiffness… Read more: Spiral Bevel Gear Meshing Stiffness Calculation Based on Finite Element Method

In this paper, I investigate the nonlinear dynamic characteristics of worm gear transmission systems, which are widely utilized in high-tech fields such as aerospace, autonomous vehicles, and smart home systems due to their compact structure, high transmission efficiency, excellent manufacturability, and self-locking properties. As the demand for higher performance in worm gears increases, improving transmission… Read more: Nonlinear Dynamic Analysis of Worm Gear Systems

In precision manufacturing, CNC gear grinding machines play a pivotal role in producing high-accuracy gears, where gear profile grinding ensures dimensional integrity and surface quality. However, operational failures in these machines, such as grinding cracks or misalignments, directly impact processing efficiency and equipment longevity. Traditional Failure Mode and Effects Analysis (FMEA) is widely used for… Read more: Improved FMEA for Hazard Analysis of Failure Modes in CNC Gear Grinding Machines

As an internal gear manufacturer, I have extensively worked on enhancing the forging processes for internal gears, which are critical components in various transmission systems. Internal gears play a vital role in ensuring efficient power transfer and durability in machinery. In this article, I will share my firsthand experience in transitioning from an open-die sleeve… Read more: Improvement of Forging Process for Internal Gears

Gear hobbing is widely adopted in manufacturing for producing high-quality spur and helical gears. Like many machining processes, it faces challenges in productivity and part quality. Physics-based simulations play a crucial role in addressing these challenges through precise process modeling, analysis, and optimization. Conventional operations like turning or milling benefit from analytical Cutter Workpiece Engagement… Read more: Three-Dimensional Dexel Model Simulation and Verification of Cylindrical Gear Hobbing

Abstract: Gear shaving is an efficient precision finishing process widely applied in gear production for machine tools, automobiles, ships, aerospace, and other industries due to its high efficiency, low cost, and strong adaptability. However, the tooth profile concave error in gear shaving has long been a technical challenge in gear manufacturing, significantly affecting the tooth surface… Read more: Tooth Profile Concave Error and Optimization of Gear Shaving Processing Considering Multi-source Factors