In this paper, the authors present methods for designing of non-circular gears, including internal and external gears with spur or helical teeth. Technology related issues that determine tooth profile calculation algorithm are described. The results presented in this paper can become groundwork for further investigations of other particular properties of non-circular gears, similar to investigations of spur, helical and bevel gears. Examples of such properties include kinematics and application of special purpose gears or issues related to strength, dynamics, tribology, etc.

There exist cases where precise simulations of contact forces do not allow modeling the gears as rigid bodies but a fully elastic description is needed. In this paper, a modally reduced elastic multibody system including gear contact based on a floating frame of reference formulation is proposed that allows very precise simulations of fully elastic gears with appropriately meshed gears in reasonable time even for many rotations. One advantage of this approach is that there is no assumption about the geometry of the gears and, therefore, it allows precise investigations of contacts between gears with almost arbitrary non-standard tooth geometries including flank profile corrections.

This study presents simulation results that show how this modal approach can be used to efficiently investigate the interaction between elastic deformations and flank profile corrections as well as their influence on the contact forces. It is shown that the elastic approach is able to describe important phenomena like early addendum contact for insufficiently corrected profiles in dependence of the transmitted load. Furthermore, it is shown how this approach can be used for precise and efficient simulations of beveloid gears.

The article reports the results of a comparative analysis made for three novel unconventional gear wheel forging processes based on the authors’ patented [5,6,21] plastic forming methods developed chiefly for the purposes of extruding hollow products as well as valves and pins. These processes are distinguished by the fact that part of the tooling elements which are normally fixed during conventional forging are purposefully set in motion. This is intended to change the conditions of friction at the metal-tool contact surface and to induce additional thermal effects due to the transformation of the plastic deformation energy into thermal energy and, as a consequence, to improve the plastic flow of metal and to reduce the force parameters of the process.

The article proposes the implementation of a novel method of plastic forming of internal toothing in flange spline sleeves. A method being the subject of Polish patent application P.416772 has been used for this purpose, which involves a combination of the scheme of the direct extrusion of a cone hollow with the die press forming of the wall to obtain a flange. The entire process takes place in a single technological sequence. The operations come one after another, so that there is no need for reheating the stock or carrying out intermediate soft annealing. The proposed method is assumed to be an alternative to the operation of press forming of internal spline sleeve toothing in a conical die [1] and to the operation of swaging on rotary swaging machines [2]. It is assumed that this method, too, is alternative to other technologies known from the literature and industrial practice, whose specifications and literature references will be indicated later on in this paper. Computer simulations of the flanged sleeve plastic forming process were performed using the commercial numerical program Forge®3D. During the numerical computations, the distributions of temperature fields were determined on the cross-section of the plastically formed product. The computations enabled also the visualization of the plastic flow of metal, especially in the toothing forming regions, and the determination of the energy and force parameters of the process.

The paper compares the geometrical surface structure of modelled tooth flanks of cylindrical gear obtained by a three dimensional simulation of gear generation with the geometrical surface structure of real gear obtained through chiselling by Fellows method. The paper presents the methodology of modelling tooth flanks of cylindrical gears in the CAD environment. The modelling consists in computer simulation of gear generation. The computer simulation of the gear generation was performed in the Mechanical Desktop environment. Metrological measurements of the real gear were carried out using a coordinated measuring machine and a profilometer.

This research highlights the vibration analysis on worm gears at various conditions of oil using the experimental set up. An experimental rig was developed to facilitate the collection of the vibration signals which consisted of a worm gear box coupled to an AC motor. The four faults were induced in the gear box and the vibration data were collected under full, half and quarter oil conditions. An accelerometer was used to collect the signals and for further analysis of the vibration signals, MATLAB software was used to process the data. Symlet wavelet transform was applied to the raw FFT to compare the features of the data. ANN was implemented to classify various faults and the accuracy is 93.3%.

The progress of additive manufacturing technology brings about many new questions and challenges. Additive manufacturing technology allows for designing machine elements with smaller mass, but at the same time with the same stiffness and stress loading capacity. By using additive manufacturing it is possible to produce gears in the form of shell shape with infill inside. This study is carried out as an attempt to answer the question which type of infill, and with how much density, is optimal for a spur gear tooth to ensure the best stiffness and stress loading capacity. An analysis is performed using numerical finite element method. Two new infill structures are proposed: triangular infill with five different densities and topology infill designed according to the already known results for 2D cantilever topology optimization, known as Michell structures. The von Mises stress, displacements and bending stiffness are analyzed for full body gear tooth and for shell body gear tooth with above mentioned types of infill structure.

In the paper presents two new patented of unconventional methods author’s and sleeve-type products of extruding [PL219182, PL221425]. The extrusion methods have been developed with the aim of reducing the energy and force parameters during the plastic forming of material. Traditional methods of extruding similar products are characterized by considerably higher extrusion force magnitudes. This results in substantial limitations and problems of an engineering nature. Moreover, the proposed methods of producing bottomed and bottomless sleeves are distinguished by the capability to minimize or totally eliminate the waste. The author’s methods of extruding long bottomless sleeves, presented herein, were used for developing a method for shaping inner toothing in spline sleeves. The theoretical analysis is based on thermomechanical simulation of the possibility of applying such processes to the extrusion of spline shafts with inner toothing. Next, the obtained results were compared with analogous parameters for classical indirect extrusion. The possibility of shaping inner toothing over the entire product length according to the proposed spline sleeve plastic forming methods was also explored.

This paper explores the influence of linear gear tip relief modification on power transmission efficiency. In real time applications gears experience transmission error (TE) during operation which increases noise and vibration and also results in increased tooth profile deformation during operation of the gear. By providing tip relief profile modification this TE can be decreased. Using MATLAB for computation and ANSYS for the simulation of deformation, stress, strain, life, and factor of safety results for the gear assemblies are obtained. Deformation results are used for the computation change in power transmission efficiency followed by the modal and harmonic analysis of the gears and gear assemblies to determine change in the first mode of natural frequency.

Achieving a reliable fault diagnosis for gears under variable operating conditions is a pressing need of industries to ensure productivity by averting unwanted breakdowns. In the present work, a hybrid approach is proposed by integrating Hu invariant moments and an artificial neural network for explicit extraction and classification of gear faults using time-frequency transforms. The Zhao-Atlas-Marks transform is used to convert the raw vibrations signals from the gears into time-frequency distributions. The proposed method is applied to a single-stage spur gearbox with faults created using electric discharge machining in laboratory conditions. The results show the effectiveness of the proposed methodology in classifying the faults in gears with high accuracy.

The paper presents the possibility of using FSW technology for joining elements of a landing gear beam of the M28 aircraft. The FSW process was performed on a 4-axis numerical machine under industrial conditions. However, before welding was carried out under industrial conditions, preliminary experimental tests were carried out under laboratory conditions. Preliminary research was carried out for AA2024-T3 aluminum sheets of 1 mm and 3 mm in thickness, joined in a lap configuration. The influence of technological and geometric parameters of the process on the quality and strength of the weld was examined. Sheet metal arrangement was analyzed. Tests were carried out for two configurations. The first of which with 1 mm sheet on the top and 3 mm sheet on the bottom and in reverse order. It has been shown that setting a thicker plate on the top gives a 40% better strength. The microhardness and microstructure of the weld were tested. During the laboratory tests, low-cycle fatigue tests of the FSW lap joint were performed. It has been shown that the FSW method can be an alternative to the riveting process in the production of aviation structure elements.