Journal of Advanced Mechanical Design, Systems, and Manufacturing (Nov 2023)
Meshing mechanism considering various combinations of assembly and manufacturing errors on face gear using a transmission-error-controlled curve
Abstract
A face gear is typically used in fishing spinning reel mechanism owing to its easy fabrication and good reel handle rotation. As face gears without tooth flank modification are sensitive to assembly errors, the fishing reel sensation becomes unstable in mass production. Previously, tooth flank modification with a transmission error (TE)-controlled curve was used to solve this problem. The TE-controlled curve stabilized the fishing reel sensation for assembling. However, in mass production, the manufacturing error of a pinion and face gear must be considered along with the assembly error. In a previous study, we analyzed all the eight error factors, including the manufacturing error, individually. Thus, we clarified that pressure angle deviation of the pinion and tooth rotational error of the face gear have a significant effect on TE. However, in mass production, these errors are combined in a complicated manner. In this study, an experiment was conducted using the L18 orthogonal array to elucidate the interaction between error factors. No peaks and troughs were observed in the curve of each factor, thus showing that there is little interaction due to the combination of factors. Although the proposed model was less affected than the conventional model by most errors, the proposed model was affected by the pressure angle deviation of the pinion and the tooth rotational error of the face gear. These results were the same as that of the single-factor experiment in the previous report. By analyzing the path of contact using a three dimensional simulation, we confirmed that uneven TE waveforms were caused by edge contact due to insufficient tooth flank modification. The unevenness in the TE waveform occurred when the factor levels of the assembly and manufacturing errors were large, when these error factors were combined, and when the amount of tooth flank modification of the face gear was small. This phenomenon was regarded as a trochoidal interference, which was caused by the contact of the tooth tip of the pinion, and it was also confirmed using prototype gears. The combination of these errors must be carefully considered in the manufacturing process. Consequently, we have elucidated that avoiding the interference due to combination of errors was significantly important to improve the fishing reel sensation.
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