Surface finish measurement systems to verify new gear manufacturing methods
To help prevent cost-intensive postprocessing, Lund University used a simulation to calculate the ideal machine parameters for a form milling cutter. This was to ensure the tool would produce tooth flanks with optimum surface quality. The research team used Bruker Alicona systems at Sandvik Coromant to validate the mathematical models and verify their suitability for practical use. "Thanks to the high working distance, we were able to measure the roughness of tooth flanks that were previously inaccessible to us," lead researcher Mattias Svahn confirms.
Comparison of measurement results and CAD data
Bruker Alicona is also used for form measurement of gears/tooth flanks. Users benefit from comparing measurement results to CAD data and positional tolerances.
Calculated roughness vs. measured roughness
The research team developed a mathematical model in order to investigate how machine parameters and possible error sources find their impact on the cut surface roughness.
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Increase efficiency in gear manufacturing with ideal surface quality
Due to global competition, cost pressure is constantly on the rise. This makes it necessary to increase the efficiency of processes in the manufacture of gearings. One of the major cost factors is post-processing, including refining steps such as grinding and honing to ensure the correct roughness of tooth flanks. This process could be minimized if it were possible to produce virtually perfect gears with optimum surface quality that need little to no post-processing. To make this a reality and ensure gears are produced with the desired roughness, it is critical to calculate the correct machine parameters for the tool used, e.g. for a form milling cutter. Roughness is chiefly determined by feed and cutting speed. These parameters also have an effect on gears' service life, fatigue and uniform transmission of motion. It is therefore of great economical interest to predict which roughness values result from different machine parameters.
How Lund University & Sandvik succeed with Bruker Alicona solution
Dimensional accuracy & surface finish measurement
- Accurate, fast and universal optical 3D measuring instrument for tolerances in the µm and sub-µm range
- Components are measured area-based and with high resolution independent of size, material, geometry, weight and surface finish
- A number of proven and new features combine the functionalities of a roughness measuring system (Ra, Rq, Rz/Sa, Sq, Sz) with the characteristics of a coordinate measuring machine