Major industrial equipment, high-end manufacturing

The largest Klindenberg bevel gear pair in China has been successfully delivered

A finished Klinberger spiral bevel gear with a diameter of 2725mm

Recently, Jiangsu Jinxiang Transmission Equipment Co., Ltd. meticulously produced the largest-diameter high-precision hard tooth face Klingenberg spiral bevel gear pair in China to date. This bevel gear pair is used in forging machines and under high-impact conditions. The diameter of the bevel gear is 2725mm, and it is in a ring-shaped structure. The wall thickness of the gear ring is only 185mm, making it a thin-walled and easily deformed component. The gear ratio of the bevel gear pair is 6.07, and the outer cone distance of the small gear is nearly 1400mm, which is a typical long cone ratio transmission.

                                                                                                                                                                            小轮TCA接触区

Thanks to the joint efforts of Jinxiang Transmission Technology, the workshop and the production department, and in accordance with the standards in key technical links such as modeling, TCA, CAM, precision milling of the machining center, and heat treatment, by fully utilizing optimization tools, the precision of the parts has all met the requirements of the drawings, and the contact area has fully achieved the TCA optimization goal. This perfectly embodies the craftsmanship spirit of meticulous workmanship. 

The main objective of modeling is to obtain the optimal contact area of the bevel gear pair. Through repeated modeling and TCA analysis, multiple control parameters are adjusted to obtain the ideal contact spots. Due to the external bevel gear pair with a nearly 1400mm long bevel gear pitch, using the traditional cutter milling tooth process is difficult to obtain the ideal contact area. Jinxiang's adopted three-dimensional precise digital model + TCA technical route can ensure obtaining a better contact area before processing, avoiding repeated trial fittings during the processing stage.

                                                                                                                                                                                大轮TCA接触区

Preparing the CAM processing program is an extremely meticulous and patient task. Since the workpiece is a thin-walled part, it undergoes significant deformation after carburizing and quenching. The deformation is large and irregular, so it is necessary to adjust the multi-axis parameters of the CAM tool path multiple times during the processing to ensure the processing accuracy and achieve the maximum effective hardened layer depth, reduce the tooth surface roughness, and ensure the wear resistance and impact resistance of the gear.

Small bevel gear tooth groove processing tool path diagram

During the processing of gears, the surface of the teeth is the core procedure. The clamping and positioning, the allocation of allowances, the selection of cutting speed and depth, and the choice of tools all require careful determination, and should be adjusted in a timely manner according to the actual processing quality during the cutting process.

Profile diagram of the cutting path for processing the teeth groove of a large bevel gear

Small bevel gear tooth surface is being machined

The bevel gear tooth surface is being machined

The small bevel gear is an integral gear shaft. Its head is the bevel gear teeth. The total length is nearly 1500mm. We placed the cylindrical part of the gear shaft in the center hole of the machine tool, minimizing the height of the protruding head to enhance the rigidity of the process system, reduce vibration, and achieve high-quality tooth surfaces.

Completed large bevel gears

The tooth accuracy of the gears reaches DIN6 level, among which the precision indicators of the gear shaft part reach DIN5, the surface roughness of the teeth reaches Ra0.8, the overall precision reaches GB6 level, and the contact spots fully comply with the TCA results.