The traditional design process for bevel gears is a costly and time consuming undertaking. First, gear design engineers must make an educated guess on how the contact pattern will perform under load. However, the only way to accurately assess this prediction is to produce a gear set, run the gears under load, and then review the contact pattern. Typically, this process must be repeated until an optimal pattern is achieved; a process that can take months to accomplish.
To address the limitations of conventional methods, Arrow Gear implemented a highly advanced system for performing contact pattern development – a system that provides a dramatic reduction in the time and expense of the process when compared to conventional methods.
This system uses a combination of state-of-the-art development software and machine tools. Among its key components are Gleason’s G-AGE, CAGE, MINIGAGE, Loaded TCA and Finite Element Analysis software packages. And for machine tools, the system utilizes Gleason Phoenix CNC Tooth Cutters and Phoenix CNC Tooth Grinders, in conjunction with a Zeiss Hofler CNC Gear Inspection System.
Using the development software, Arrow Gear engineers can build virtual models to predict how the gear will perform in actual operation. This in turn generates the settings to be used by the machine tools. In addition, these settings for the machine adjustments are automatically downloaded to the machine tools, greatly reducing the time spent on setup. Perhaps the most dramatic aspect of this system is that ideal settings of the machine tools which are required to produce the desired contact pattern are typically achieved in the first or second attempt on the gear manufacturer’s shop floor.
An interesting footnote on this system is that Arrow was the first gear company in the world to utilize this type of comprehensive or Closed Loop system.
In essence, this system eliminates the trial and error process that was once required – a process that could take up to 6 months. With the unprecedented reduction in development time, Arrow Gear is able to provide a significant cost savings to the customer - approximately ½ million dollars per customer in some cases. This capability also allows the customer to introduce their product to the market much faster than was previously possible.
Having pioneered this innovative technology, and with a long list of successful projects, Arrow is now sought after by some of the top OEMs in the aerospace industry to provide this service.