Abstract
This paper focuses on the input shaft of a gearbox assembly from a well-known automobile company. The company was facing a problem of noise and vibrations in the reverse gear section of the input shaft. The problem was the formation of nick at the gear root of the reverse gear. A nick is plus material anywhere on the part. The reverse gear section undergoes two machining operations, viz. shaping and shaving, and therefore, these two processes are focused in this work. The experiments are designed as per Taguchi’s L9 orthogonal array with two replications of each experiment. Total 27 experiments were carried out for the process optimization by varying three control factors, viz. cutter span width, shaping over ball diameter, and shaving over ball diameter, and by considering nick value as the response. After the analysis, we found that the response is best when cutter span width is 69.450 mm, shaping over ball diameter is 33.636 mm, and shaving over ball diameter is 33.450 mm. The optimum condition for the best results is calculated and validated.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Similar content being viewed by others
References
Radzevich, S.: Practical Gear Design and Manufacture, 2nd edn. CRC Press, Taylor & Francis Group, New York, pp. 1–16 (2012)
Gupta, K., Laubscher, R., Jain, N.: Recent developments in sustainable manufacturing of gears: a review. J. Clean. Prod. 112, 3320–3330 (2016)
Tsay, C.B., Liu, W.Y., Chen, Y.C.: Spur gear generation by shaper cutters. J. Mater. Process. Technol. 104, 271–279 (2000)
Erkorkmaz, K., Katz, A., Hosseinkhani, Y., Plakhotnik, D., Stautner, M., Ismail, F.: Chip geometry and cutting forces in gear shaping. CIRP Ann. Manuf. Technol. 65, 133–136 (2016)
Kim, J., Kim, D.: The development of software for shaving cutter design. J. Mater. Process. Technol. 59, 359–366 (1996)
Hung, C., Liu, J., Chang, S., Lin, H.: Simulation of gear shaving with considerations of cutter assembly errors and machine setting parameters. Int. J. Adv. Manuf. Technol. 35, 400–407 (2007)
Gosh, G.: Gear metrology. Ann. CIRP 52, 659–695 (2003)
Bhilawade, T., Sapkal, S.: Experimental analysis on input shaft reverse gear section. In: Proceedings of 3rd National Conference on Recent Trends in Mechanical Engineering, pp. 240–245 (2018)
Acknowledgements
Authors are thankful to authorities and staff of Fiat India Automobiles Limited, Pune, for providing the facilities and necessary support for experimentation.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2020 Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Sapkal, S.U., Bhilawade, T.A. (2020). Elimination of Nick Defect by Process Optimization for Input Shaft Reverse Gear Section. In: Venkata Rao, R., Taler, J. (eds) Advanced Engineering Optimization Through Intelligent Techniques. Advances in Intelligent Systems and Computing, vol 949. Springer, Singapore. https://doi.org/10.1007/978-981-13-8196-6_63
Download citation
DOI: https://doi.org/10.1007/978-981-13-8196-6_63
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-13-8195-9
Online ISBN: 978-981-13-8196-6
eBook Packages: Intelligent Technologies and RoboticsIntelligent Technologies and Robotics (R0)