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Design Assistance

 

Custom Gear Optimization and Design Assistance 

Gear Optimization 

Below is an example of our analysis on a customer’s existing design which ultimately resulted in increased performance and longer life of the gear set.

 

3D Design

Figure 1 - 3D Model

 

Milwaukee Gear<sup>™</sup>brand's 2D Model

Figure 2 - 2D Model Note: mesh is not centered between bearings


Milwaukee Gear<sup>®</sup> brand's No Micro Geometry Corrections

Figure 3 - No Micro Geometry Corrections


Figure 4 - Load Distribution and intensity without Optimized Micro Geometry

Figure 4 - Load Distribution and intensity without Optimized Micro Geometry 


Figures 1 to 4 are an example where Milwaukee Gear worked with a customer who was not getting satisfactory performance from their existing design. 

 

The customer’s existing design did not call for any micro geometry modifications, the resulting load distribution for non-modified teeth in Figure 4 was causing macro pitting. 

 

Figure 5 - Optimized Micro Geometry

Figure 5 - Optimized Micro Geometry


Figure 6 - Shaft Bending causing Mesh Misalignment

Figure 6 - Shaft Bending causing Mesh Misalignment


Figure 7 - Load Distribution and Intensity

Figure 7 - Load Distribution and Intensity


In Figure 5, Milwaukee Gear suggested lead and profile modifications based on LVR analysis of the gear train. These suggestions were based on the shaft deflection in Figure 6. After making the suggested micro geometry corrections in Figure 5, the load distribution in Figure 7 eliminated the pitting and increased the performance resulting in longer life without increasing the cost of the gear set.