J.R. Davis - GEAR MATERIALS,PROPERTIES, AND MANUFACTURE - Book Information

© 2005 ASM International. All Rights Reserved.
Gear Materials, Properties, and Manufacture (#05125G)

Preface   . . . . vii

Introduction to Gear Technology

Chapter 1 Basic Understanding of Gears  . . . . . . . . 1
Gear Nomenclature  . . . . . . . . . . . . . . . . 1
Types of Gears  . . . . . . . . . . . . . . . . . . . 5
Proper Gear Selection  . . . . . . . . . . . . . . 8
Basic Applied Stresses  . . . . . . . . . . . . . 9
Strength  . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear Materials  . . . . . . . . . . . . . . . . . . . 12
Gear Manufacturing Methods  . . . . . . . 13
Heat Treating  . . . . . . . . . . . . . . . . . . . . 16
Through Hardening and Case Hardening . . . . . . . . . 17

Chapter 2 Gear Tribology and Lubrication  . . . . . 19
Gear Tribology  . . . . . . . . . . . . . . . . . . 19
Lubrication Regimes  . . . . . . . . . . . . . . 19
Classification of Gear Tooth Failure Modes . . . 21
Lubrication-Related Failure  . . . . . . . . 21
Elastohydrodynamic Lubrication  . . . . 27
Lubricant Selection  . . . . . . . . . . . . . . . 31
Oil Lubricant Applications  . . . . . . . . . 32
Selection of Gear Lubricant Viscosity  33
Application of Gear Lubricants  . . . . . . 33
Case History: Failure of a 24-Unit Speed-Increaser Gearbox . 35
Gear Materials
Chapter 3 Ferrous and Nonferrous Alloys  . . . . . . 39
Wrought Gear Steels  . . . . . . . . . . . . . . 39
Surface-Hardening Steels  . . . . . . . . . . 40
Through-Hardening Steels  . . . . . . . . . 44
Gear Steel Requirements  . . . . . . . . . . . 44
Processing Characteristics of Gear Steels . . .  45
Bending Fatigue Strength of Carburized Steels . . 46
Other Properties of Interest for Carburized Steels 62
Other Ferrous Alloys for Gears  . . . . . . 66
Nonferrous Alloys  . . . . . . . . . . . . . . . . 72

Chapter 4 Plastics  . . . . . . . . . . . . . .  . 77
General Characteristics of Plastic Gears . . . . . 77
Classification of Plastics for Gear Applications . . . . . 77
Metals versus Plastics  . . . . . . . . . . . . . 78
Plastic Gear Materials  . . . . . . . . . . . . . 79
Plastic Gear Manufacture  . . . . . . . . . . 82

Gear Manufacture

Chapter 5 Machining, Grinding, and Finishing  . . 89
Machining Processes for Gears  . . . . . . 90
Selection of Machining Process  . . . . . 98
Cutter Material and Construction  . . . 104
Speed and Feed  . . . . . . . . . . . . . . . . . 107
Cutting Fluids  . . . . . . . . . . . . . . . . . . 111
Comparison of Steels for Gear Cutting . . . . . . . 113
Computer Numerical Control (CNC) Milling and Hobbing Machines . . . . . . . . 113
Grinding of Gears  . . . . . . . . . . . . . . . 114
Honing of Gears  . . . . . . . . . . . . . . . . 122
Lapping of Gears  . . . . . . . . . . . . . . . . 124
Superfinishing  . . . . . . . . . . . . . . . . . . 125

Chapter 6 Casting, Forming, and Forging  . . . . . 129
Casting  . . . . . . . . . . . . . . . . . . . . . . . . 129
Forming  . . . . . . . . . . . . . . . . . . . . . . . 131
Forging  . . . . . . . . . . . . . . . . . . . . . . . 133

Chapter 7 Powder Metallurgy  . . . . . . . . . . . . . . . 139
Capabilities and Limitations  . . . . . . . 140
Gear Forms  . . . . . . . . . . . . . . . . . . . . 142
Gear Tolerances  . . . . . . . . . . . . . . . . . 143
Gear Design and Tooling  . . . . . . . . . 144
Gear Performance  . . . . . . . . . . . . . . . 147
Quality Control and Inspection  . . . . . 148
Examples of P/M Gears  . . . . . . . . . . . 149
Heat Treatment of Gears

Chapter 8 Through Hardening  . . . . . . . . . . . . . . 155
Through-Hardening Processes  . . . . . 155
Through-Hardened Gear Design  . . . . 157
Hardness Measurement  . . . . . . . . . . . 157
Distortion of Through-Hardened Gears . . . . 158
Applications  . . . . . . . . . . . . . . . . . . . 158
Case History: Design and Manufacture of a Rack .  . 158

Chapter 9 Carburizing  . . . . . . . . . . . . . . . . . . . . . 163
Gas Carburizing: Processing and Equipment . . . .. . 163
Quenching and Hardening  . . . . . . . . . 166
Tempering of Carburized and Quenched Gears . . .  168
Recarburizing  . . . . . . . . . . . . . . . . . . 169
Cold Treatment  . . . . . . . . . . . . . . . . . 169
Selection of Materials for Carburized Gears . . . 169
Carbon Content and Case Properties  . 175
Core Hardness of Gear Teeth  . . . . . . 181
Problems Associated with Carburizing . . . . . . . . 184
Heat Treat Distortion of Carburized and Hardened Gears . 188
Grinding Stock Allowance on Tooth Flanks to Compensate for Distortion . . . . 201
Shot Peening of Carburized and Hardened Gears . .  208
Applications and Costs  . . . . . . . . . . . 211
Vacuum Carburizing  . . . . . . . . . . . . . 212

Chapter 10 Nitriding  . . . . . . . . . . . . . . . . . . . . . . . . 227
The Gas Nitriding Process  . . . . . . . . . 227
Controlled Nitriding  . . . . . . . . . . . . . 240
Ion Nitriding  . . . . . . . . . . . . . . . . . . . 241

Chapter 11 Carbonitriding  . . . . . . . . . . . . . . . . . . . 245
Applicable Steels and Applications  . . 246
Depth of Case  . . . . . . . . . . . . . . . . . . 246
Hardenability of Case  . . . . . . . . . . . . 246
Quenching and Tempering  . . . . . . . . 247
Distortion  . . . . . . . . . . . . . . . . . . . . . . 247

Chapter 12 Induction and Flame Hardening  . . . . 249
Induction Hardening  . . . . . . . . . . . . . 249
Flame Hardening  . . . . . . . . . . . . . . . . 253
Failure Analysis, Fatigue Life Prediction, and Mechanical Testing

Chapter 13 Gear Failure Modes and Analysis  . . . 257
Classification of Gear Failure Modes  257
Fatigue Failures  . . . . . . . . . . . . . . . . . 257
Impact  . . . . . . . . . . . . . . . . . . . . . . . . 271
Wear  . . . . . . . . . . . . . . . . . . . . . . . . . 273
Scuffing  . . . . . . . . . . . . . . . . . . . . . . . 275
Stress Rupture  . . . . . . . . . . . . . . . . . . 276
Causes of Gear Failures  . . . . . . . . . . . 276
Conducting the Failure Analysis  . . . . 277
Examples of Gear Failure Analysis  . . 283

Chapter 14 Fatigue and Life Prediction  . . . . . . . . 293
Gear Tooth Contact  . . . . . . . . . . . . . . 293
Gear Tooth Surface Durability and Breakage . .. 296
Life Determined by Contact Stress  . . 297
Life Determined by Bending Stress  . 302
Gear Tooth Failure by Breakage after Pitting . . 304
Flaws and Gear Life  . . . . . . . . . . . . . 306
Bores and Shafts  . . . . . . . . . . . . . . . . 307

Chapter 15 Mechanical Testing  . . . . . . . . . . . . . . . 311
Common Modes of Gear Failure  . . . . 311
Stress Calculations for Test Parameters . 312
Specimen Characterization  . . . . . . . . 315
Tests Simulating Gear Action  . . . . . . 316
Gear Power-Circulating (PC), or Four-Square, Tests .  323

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29 August 2023

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Ud. 5.9.2023

Pub. 15.3.2020