In the case of TV products, space constraints and design requirements make it advantageous to use a worm gear that has a small volume and a self-locking function. Single enveloping worm gear teeth are classified as ZA, ZN, ZK, ZI, and ZC according to international standards. However, combining worm shafts and worm wheels with different tooth profiles can significantly worsen meshing transmission errors and reduce the lifespan of the worm gear. Despite these challenges, due to processing limitations, ease of manufacturing, and cost reduction, combinations of worm shafts and worm wheels with different tooth profiles are still considered. In this study, we confirmed the meshing transmission error for a worm gear that combined a ZA tooth shape worm shaft with a ZI tooth shape worm wheel. Additionally, we examined the contact stress and fatigue life characteristics of the material combinations using finite element analysis (FEM).
Development and research on electric vehicles in power transmission system are increasing as the demand for ecofriendly and autonomous vehicles increases across the industry. In order to reduce noise, research on high efficiency and low noise due to electrification of the gearbox system is being actively conducted, such as applying design technology to optimize the shape of the gear and increase rigidity. In particular, research on low noise is active because the noise of the electric gearbox could be easily recognized in a vehicle, even with small noise due to its frequency characteristics. Therefore, in this study, effects of main specifications of gears on noise and power loss were studied and analyzed through a Parametric Study. Characteristics of the proportional relationship between noise and power loss according to major specifications were analyzed. Based on study results, NVH analysis in the gear system was performed. After that, actual data were secured through test measurements and a noise reduction effect of 4.4 dB was confirmed.
The gear overlap ratio shows the characteristics of the spur gear and the helical gear and varies according to the torsional angle. The gear ratio, tooth width, and center distance, which are restricted in a space of performance and manufacturing and design in the gearbox, are fixed. A parametric study on modules, the number of teeth, and torsion angles was conducted to analyze the relationship between the overlap ratio and PPTE. Then, contact analysis was performed by correcting the tooth profile to improve the transmission error. Contact analysis was performed through correction of the tooth modification to improve transmission error, and the noise was analyzed according to the overlap ratio by applying a noise prediction equation.
Citations
Citations to this article as recorded by
Study on the Modification of the Contact Pattern and Teeth Shape of Tapping Device Drive Gears Sung-Min Moon, Yong-Woo Park, Do-Young Lee, Sung-Ki Lyu Journal of the Korean Society of Manufacturing Process Engineers.2025; 24(9): 76. CrossRef
A Study on the High Efficiency and Low Noise Design of Electric Industrial Gearboxes Nam Yong Kim, Jin-Uk Baek, Sung Ki Lyu Journal of the Korean Society for Precision Engineering.2024; 41(4): 243. CrossRef
Optimal Design of Surface Pressure Strength to Prevent Gear System Pitting Phenomenon Gi-Myung Gwak, Jin-Uk Baek, Nam-Yong Kim, Sung-Ki Lyu Journal of the Korean Society of Manufacturing Process Engineers.2024; 23(1): 76. CrossRef
Development of a Prediction Model for the Gear Whine Noise of Transmission Using Machine Learning Sun-Hyoung Lee, Kwang-Phil Park International Journal of Precision Engineering and Manufacturing.2023; 24(10): 1793. CrossRef
The gear has a wide range of transmitted force as various gear ratios are possible using a combination of teeth. It can transmit power reliably and cause relatively little vibration and noise. For this reason, the application of reducers of electric vehicles is being expanded. Vibration noise generated from gears is propagated into the quiet interior of a vehicle, causing various claims. In most gear studies, transmission error has been pointed out as the main cause of vibration noise of gears. Transmission errors have various causes, including design factors, manufacturing factors, and assembly factors. In general, when predicting transmission error through finite element analysis, design factors play an important role without considering manufacturing factors or assembly factors. In this study, relationships among important design variables (gear module, compensation rate, load torque, and transmission error) in gear design were investigated using analytical and experimental methods. In addition, a method of predicting gear meshing stiffness through the predicted gear transmission error was proposed to obtain variation of meshing stiffness due to changes of gear design parameters.
Citations
Citations to this article as recorded by
Development of a Prediction Model for the Gear Whine Noise of Transmission Using Machine Learning Sun-Hyoung Lee, Kwang-Phil Park International Journal of Precision Engineering and Manufacturing.2023; 24(10): 1793. CrossRef
Nowadays, noise, vibration, and harshness (NVH) is a comprehensive issue related to manufacturing quality, it gives the purchaser the most direct and superficial feeling. Following economic development, the improvement of people’s living standards, and the expansion of the export market, it has become urgent to develop and produce some better NVH performance motorcycles. In this paper, the transmission of a scooter gearbox is modeled and analyzed by software. Then, the first helical gear pair of the gearbox was investigated through static analysis. Lastly, optimized modification was verified using B&K testing equipment in the semi-anechoic room. The comparison of the simulation to prototype during testing showed a good correlation, which means simulation optimization can greatly improve the research and development efficiency of the transmission system.
Citations
Citations to this article as recorded by
A Study on the Optimum Design of Planetary Gear Train for Air-Starting Motor Nam-Yong Kim, Seong-Bae Park, Sung-Ki Lyu Journal of the Korean Society of Manufacturing Process Engineers.2022; 21(12): 135. CrossRef
Performance Test for a Multi-stage Planetary Gear Module in a Hydraulic Winch Kyu Tae Park, Young Rak Yoo, Jong-Hak Lim, Sung-Hoon Kim, Ho Seong Lee, Chul Ki Song Journal of the Korean Society of Manufacturing Process Engineers.2020; 19(10): 31. CrossRef
A Study on the Optimal Design of Drive Gear for Transfer Gearbox MyeongJin Song, MyeongHo Kim, Zhen Qin, DongSeon Kim, NamSool Jeon, SungKi Lyu Journal of the Korean Society for Precision Engineering.2019; 36(2): 121. CrossRef
Study on the Reduction of Gear Whine Noise in Diesel Engine Gear Train Qi Zhang, Yong Bo Wang, Jian Hua Lv, Zhong Gang Zhu, Zhen Qin, Sung Ki Lyu Journal of the Korean Society for Precision Engineering.2019; 36(9): 867. CrossRef
A popular approach to optimize the performance of a gear transmission system is the modification of the gear tooth microgeometry, which includes the intentional removal of material from the gear teeth flanks, so that the shape is no longer a perfect involute. Such modifications compensate teeth deflections under load, and the resulting transmission error is minimized under a specific torque. Therefore, micro-geometry modifications can be applied on the involute (or profile) and lead of the gear teeth. In order to study the tooth micro-geometry optimization, this research selected a mass produced planetary gear type drive reducer as a prototype. The original design was modeled by a commercial software named Romax Designer, which analyzes and optimizes different types of gear power transmission systems. The series analysis results obtained reveal some anomalies that require modification. Based on the result, optimization and gear tooth modification were done to deal with the load distributions on gear tooth, gear durability problem, safety factor and bearing life problem. This thesis presents the outstanding performance improvement obtained after such optimization.
Citations
Citations to this article as recorded by
Development of a Prediction Model for the Gear Whine Noise of Transmission Using Machine Learning Sun-Hyoung Lee, Kwang-Phil Park International Journal of Precision Engineering and Manufacturing.2023; 24(10): 1793. CrossRef
Influence of Open Differential Design on the Mass Reduction Function Mirko Karakašić, Pejo Konjatić, Hrvoje Glavaš, Ivan Grgić Applied Sciences.2023; 13(24): 13300. CrossRef
Large Curvic Coupling Gear for Ultraprecision Angle Division Using FEM Yoon-Soo Jung, Jia-Chen Gao, Gyung-Il Lee, Ku-Rak Jung, Jae-Yeol Kim International Journal of Precision Engineering and Manufacturing.2021; 22(3): 495. CrossRef
A Review of Recent Advances in Design Optimization of Gearbox Zhen Qin, Yu-Ting Wu, Sung-Ki Lyu International Journal of Precision Engineering and Manufacturing.2018; 19(11): 1753. CrossRef
Simulation and Experimental Analysis for Noise Reduction of a Scooter Gearbox Qi Zhang, Jing Zhang, Zhong Hua Liu, Jian Hua Lv, Zhen Qin, Sung Ki Lyu Journal of the Korean Society for Precision Engineering.2018; 35(8): 777. CrossRef
First
Prev
