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Gear honing is a method to ensure high quality of vehicle gear teeth lateral faces used primarily for batch and mass production. Gear hones are used for this operation. Both the service life of vehicle systems and the vehicle noise level depend on the gear’s parameters accuracy and machining quality. Effectiveness of using gear hones depends mainly on the hardness and elasticity modulus of their composite material. In terms of the elasticity modulus, gear hones can be hard and elastic, depending on the bonding agent type. Some increase in roughness of the gear teeth lateral faces was observed at decreased hardness of the hard gear hone material due to accelerated pitting of abrasive particles. As the gear hone material elasticity degree increased with simultaneous hardness decrease, roughness decreased significantly, even at an increased abrasive grit size, as a result of alignment of the abrasive grain peaks along the supporting surface, extended contact time of the grains and machined surface, contact pattern area and fullness of machining; a favorable grid of machining marks is available. Though removal of such coarse irregularities as dents and burrs by hard gear hones is more efficient. Overall reduction of the noise level of vehicle gears is observed, as well. Correspondence of the obtained experimental results to the suggested theoretic criterion of quality and machining fullness.

Machining quality improvement and noise reduction of vehicle gears