Projects

1Design and Manufacturing of Asymmetric Spur Gear Forging Die

The gears, which are the basic elements in mechanical power transmission, have been in use for about 4000 years and have made great developments in the last century to suit the needs of modern technology. In recent years, the reductions of energy consumptions and environmental factors (reduction of carbon emissions) have gained importance, thus increasing the studies of reducing the weight of mechanical systems and increasing their efficiency. There are many important areas ranging from gearboxes for helicopters and motor vehicles to generators, lifting gears to gear pumps, work focusing on gear design and manufacturing with high precision and high efficiency. The use of asymmetric gears instead of standard gears is considered an innovative approach to this area. The production of the asymmetric gear profile by the conventional thread cutting method is dependent on the cutting tool design and the machining process, which limits the tooth profile. In the production of asymmetric gears, the use of precision forging technology will enable the production limitations stemming from the profile to be removed and the gears with high strength to be produced efficiently. For this purpose, the design of asymmetric gear forging dies, modeling of material flow and design of the forging process will be realized.
Prediction of the exact behavior of the enclosed die forging process is becoming increasingly essential and it also important to optimize the process design to reduce the required load and consumed energy [1]. Precision forging is a field in which decision support systems can be effectively and widely applied and depends on knowledge and rules derived from the past experience of forging die design engineers. Precise components are becoming quite important in attempts to reduce costs and improve reliability. There are thus many application areas in which the rules themselves become inherent to the parts or the processes. In forging die design, dimensional accuracy is one of the main goals [2]. But, there are many important parameters for designing forging die [3]. The process has been successfully applied to bevel, spur and helical gears in the near past. The process may be applied to the asymmetric gears with a proper die and process design. Precision forging technology facilitates the mass production of gears with many advantages in terms of cost and quality [4].
The purpose of this study is to design and manufacture of asymmetric spur gear forging dies. The load requirement and the resulting die stresses are determined by using finite element simulations and the die components will be designed accordingly. The die components will be manufactured using CNC machining, wire EDM cutting and/or laser cutting methods. A prototype asymmetric gear (made of a soft material like lead or plasticine) will be manufactured to validate the designed die.

Supervisor : Prof. Dr. Omer Eyercioglu

Duration : 24 Months

Supporting Organization: TUBITAK

 

2MA.Vision.Gauge: Gear Measurement Software Developing

Asymmetric gears have been attracting an increased interest in the industrial gearbox applications. This is because of their inherent advantages over symmetrical gears. However, the measurements of the asymmetric gears have difficulties due to the asymmetry of tooth profile. In this study, a non-contact measurement method based on image processing to measure the asymmetric spur gear is presented. The digital image of the asymmetric spur gear is captured by the CMOS camera and the software is developed by using Python and as OpenCV image processing library. Some digital image processing techniques and algorithms are used, including distortion correction, frame resizing, color conversion, median filter, binarization, edge detection, and sub-pixel fitting arithmetic. According to the shape feature of the asymmetrical gear, some basic principles such as fit to least squares, Hough transformation and Bresenham drawing circle were applied and the algorithm for measurement of the number of teeth, tooth width and height, addendum, dedendum and pitch diameters, and tooth profile errors was developed. The theoretical gear dimensions and the 3D CMM measurements were compared with the image processing results. The results show that this method satisfies the requirements of real-time inspection of asymmetric gears.

Supervisor : Prof. Dr. Omer Eyercioglu

Duration : 24 Months

Supporting Organization: (Gaziantep University) BAPYB

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3MA.Die.ShrinkFit.Designer: Forging Die Parameter Calculation Software
Details coming soon!