technical instruction of apex rack and pinion instruction of apex ra… · technical instruction of...
TRANSCRIPT
Technical Instruction
of
APEX Rack and Pinion
Confidential! For APEX Agents only!
APEX DYNAMICS, INC.
2017.04.
Content
1
1. General Instruction of Rack
2. Physics and Technology of Rack
3. Quality Policy of APEX Rack
4. Introduction of Induction Hardening
5. Specification of APEX Rack
6. General Instruction of APEX Pinion
7. Selection of Rack and Pinion
2
5
20
27
41
71
86
Page
1. Trend in Industry (especially Automation and CNC machine tools)
1-1. Function of the rack switches from pure movement or power transmission
over to accurate positioning, even without optical scale or linear scale.
1-2. Replacement of ball-screw
Moving speed on the rack is much higher than that on the ball-screw.
A long ball-screw tends to hang down in the middle part which is
unfavorable for a smooth and high-speed movement.
Rack can be connected to any length while the ball-screw length is limited.
While the ball-screw hangs only via both ends in the machine, rack is fully
fixed on the machine bed, so less influence by thermal expansion.
By racks, it’s easier to apply lubrication and rack has a longer life-time.
2. Requirement from Industry
High precision, high speed, high rigidity, low noise, wearing resistance
1. General Instruction of Rack
2
1. General Instruction of Rack
3
Module Number of Rack
Pitch
Circle
Pitch d
Pitch
z = Teeth No.
d = Pitch Circle Diameter
Module No. M = d / z
Pitch P = (d x π) / z = π x M
4
Pitch of Rack
1. General Instruction of Rack
θ
PitchHelical
PitchStraight
PitchHelical Cos θ
θ = 19°31’42” (19.5283°)
PM3 H Cos (19.5283°)
PM3 S
Cos (19.5283°)
π x 3
10.000014 mm
PitchStraight
PitchHelical
5
Physics of Long Metal Bar
Thermal Expansion 1°C difference the 1000mm length
metal bar changes ~ 12 μm.
Machining on Teeth
& Sides
Inducing heat and internal tension,
leading to deformation and torsion
Teeth on one Side Asymmetry in geometry,
leading to deformation and torsion
Heat-Treatment and
Induction Hardening
Leading to deformation and torsion
Important requirement of high precision rack :
Geometrical Accuracy
Heat-Treatment and Hardening Process
Geometrical tolerance of high precision rack = ~10 μm
2. Physics and Technology of Rack
6
Requirement and Reason Technology needed
Good Straightness, Less Torsion
• Influence the accuracy of pressure angle, helical
angle and pitch error
• Influence the gear coupling with pinion
• To avoid re-straightening work after long-term
stock due to slowly out-let of internal tension
Heat-Treatment
Straightening
Machining on all sides
Teeth milling and grinding
Teeth induction hardening
Quality of Rack / Geometry
τ L
L
q
2. Physics and Technology of Rack
7
2. Physics and Technology of Rack
Measurement in Free Position Measurement in Fixed Position
Quality of Rack / Straightness
By
20°C
!!
8
2. Physics and Technology of Rack
Quality of Rack / Straightness
1000 mm Rack Q4 ~ Q6 Q6M Q8 ~ Q9 Q10
Free Fixed Free Fixed Free Fixed Free Fixed
M1 ~ M2, milled - - 0.45 0.04 0.45 0.05 0.5 0.08
M1 ~ M2, ground 0.4 0.02 - - - - - -
M3 ~ M6, milled - - 0.45 0.04 0.45 0.05 0.5 0.08
M3 ~ M6, ground 0.3 0.02 - - - - - -
M8 ~ M12, milled - - 0.45 0.04 0.45 0.05 0.5 0.08
M8 ~ M12, ground 0.25 0.02 - - - - - -
APEX declares : (mm)
9
Requirement and Reason Technology needed
Good Parallelism and Perpendicularity
• Influence the accuracy of pressure angle, helical
angle and pitch error.
• Influence the gear coupling with pinion.
Heat-Treatment
Straightening
Machining on all sides
Teeth milling and grinding
Teeth induction hardening
Quality of Rack / Geometry
2. Physics and Technology of Rack
Quality
Cross-Section
Q4 / Q5H / Q5 Q6 Q6M Q8 / Q9 Q10
>10 ~ 16 0.004 0.006 0.006 0.010 0.015 0.025 0.025 0.040 0.040 0.060
>16 ~ 25 0.005 0.008 0.008 0.012 0.020 0.030 0.030 0.050 0.050 0.080
>25 ~ 40 0.006 0.010 0.010 0.015 0.025 0.040 0.040 0.060 0.060 0.100
>40 ~ 63 0.008 0.012 0.012 0.020 0.030 0.050 0.050 0.080 0.080 0.120
>63 ~ 100 0.010 0.015 0.015 0.025 0.040 0.060 0.060 0.100 0.100 0.150
>100 ~ 160 0.012 0.020 0.020 0.030 0.050 0.080 0.080 0.120 0.120 0.200
(mm) APEX declares :
10
Requirement and Reason Technology needed
Accurate Pressure Angle α and Helical Angle β
• Optimizing gear-coupling with pinion
• Optimizing transmission of torque or feed force
• Good for high speed, low noise, less wearing,
longer life-time
Heat-Treatment
Straightening
Machining on all sides
Teeth milling and grinding
Teeth induction hardening
Right-hand helical Left-hand helical
β α
α = 20°
β = 19°31’42” (19.5283°)
or 0° (straight teeth)
Standard
2. Physics and Technology of Rack
Quality of Rack / Geometry
11
Why the Helical Angle = 19°31’42” (19.5283°) ??
PitchHelical
β
PitchHelical
PitchStraight
PitchHelical Cos β
β = 19°31’42” (19.5283°)
PH M3 Cos (19.5283)
PS M3
Cos (19.5283)
π x 3
10.000014 mm
2. Physics and Technology of Rack
Teeth No.
PH M6 = 20.00003 mm x 50 = 1000.0015 mm
PH M12 = 40.00006 mm x 25 = 1000.0015 mm
PH M2 = 6.66668 mm x 150 = 1000.0020 mm
PH M4 = 13.33335 mm x 75 = 1000.0013 mm
PH M8 = 26.66670 mm x 36 = 960.0012 mm
PH M5 = 16.66669 mm x 60 = 1000.0014 mm
PH M10 = 33.33338 mm x 30 = 1000.0014 mm
12
Requirement and Reason Technology needed
Accurate Over Pin Height H
• A measure of accuracy of teeth profile
• Optimizing gear-coupling with pinion
• Influence on backlash between rack and pinion
Heat-Treatment
Straightening
Machining on all sides
Teeth milling and grinding
Teeth induction hardening
Quality of Rack / Geometry
2. Physics and Technology of Rack
* Pin Diameter depending on Mn.
Mn = 3 H
*
13
Requirement and Reason Technology needed
Low Single Pitch Error Es
Low Total Pitch Error Et
• High positioning accuracy
• Optimizing gear-coupling with pinion
• Low noise, less wearing, longer life-time
• Influence on backlash
Heat-Treatment
Straightening
Machining on all sides
Teeth milling and grinding
Teeth induction hardening
Quality of Rack / Geometry
Total Pitch Error Et is to be measured between the first and the last tooth of a rack.
Ps Ps Single Pitch
2. Physics and Technology of Rack
14
Requirement and Reason Technology needed
Rigidity / Material Hardness
• High strength of rack / High strength of teeth
• No deformation during gear coupling with Pinion
• Transmission of high torque or high feed force
• High speed, less wearing, long life-time
Heat-Treatment
Teeth induction hardening
F
Torque
Quality of Rack / Heat-Treatment and Hardness
2. Physics and Technology of Rack
15
Requirement and Reason Technology needed
High Surface Hardness Hs
• High strength of rack / High strength of teeth
• Transmission of high torque or high feed force
• High wearing resistance
Heat-Treatment
Induction hardening
Teeth grinding Thickness of Hardened-Layer L
• Preserve accuracy and long lift-time
Symmetry of Hardened-Layer on teeth profiles
• Preserve accuracy and long lift-time in both
moving directions on the rack
Quality of Rack / Heat-Treatment and Hardness
2. Physics and Technology of Rack
Hs Hs
L
Bad Induction Hardening
Bad Teeth Grinding
Unqualified !!
16
Requirement and Reason Technology needed
Low Surface Roughness
• Low noise / High speed
• Low wearing / Long life-time
Induction hardening
Teeth grinding
Quality of Rack / Heat-Treatment and Hardness
2. Physics and Technology of Rack
(μm)
Profile Lead
Quality Q4 ~ Q6 Q6M Q8 ~ Q9 Q10
Lead Ra ≤ 0.5 Ra ≤ 0.5 Ra ≤ 1.0 Ra ≤ 1.6
Profile Ra ≤ 1.0 Ra ≤ 1.0 Ra ≤ 3.0 Ra ≤ 6.3
Side Ra ≤ 1.25 Ra ≤ 2.0 Ra ≤ 2.0 Ra ≤ 2.0
APEX declares :
17
Requirement and Reason Technology needed
Low Remaining Magnet
• Prevent adhesion of particles between the rack
and pinion leading to pitting and damage the teeth.
• Smooth running
• Preserve accuracy and long lift-time
Degauss Device
Quality of Rack / Rest Magnet
2. Physics and Technology of Rack
Magnet
Particle Particle
Each APEX rack has been
degaussed down to under
10 ± 3 Gauss before delivery !!
18
Requirement and Reason Technology needed
Magnetic Crack Inspection
• Preserve accuracy
• Guarantee of long life-time
Magnetic Crack Inspection
Device
APEX rack has been check by
Magnetic Crack Inspection!
Quality of Rack / Rest Magnet
2. Physics and Technology of Rack
19
Quality of Rack
2. Physics and Technology of Rack
All the requirements mentioned above are aiming to :
High Positioning Accuracy
High Speed Low-Noise Transmission
High Torque and Feed Force
Long Life-Time
3. Quality Policy of APEX Rack
APEX is the ONLY ONE rack manufacturer in the
world who defines explicitly and clearly :
The geometrical tolerance in the engineer-
ing drawing and in the QC-standard
(for all dimensions, helical and pressure
angle, straightness, parallelism and
perpendicularity…)
The surface roughness of the teeth
The hardness and thickness of the hardened
layer on the teeth
20
21
3. Quality Policy of APEX Rack
Declaration of Tolerance in Catalog
** All measurements to do by 20°C
** Total Pitch Error shown per 1000 mm
22
3. Quality Policy of APEX Rack
Declaration of Tolerance / Angular Deviation
Length Deviation
Angular
Deviation
Angular
Deviation
Length Deviation
Declaration of Tolerance / Angular Deviation
Pressure Angle Helical Angle
23
Declaration of Tolerance / Over-Pin-Height Deviation
* Pin Diameter depending on Mn.
Mn = 3
H
*
H
H
3. Quality Policy of APEX Rack
OPH = a measure of the precision of teeth
24
Declaration of Tolerance / Over-Pin-Height Deviation Error Demo !!
3. Quality Policy of APEX Rack
(1) To mill or grind the back side of rack after the teeth grinding, in order to
achieve the exact Over-Pin-Height,. Incorrect way !!
d
H H
d OPH OK, Teeth OK OPH OK, Teeth error
(2) To mill or grind the back side of rack, the top
of teeth would be taken as reference surface.
The teeth tops are NOT ground simultaneously
with the teeth profile, hence the OPH is still NOT
correct in this way.
25
Declaration of Tolerance / Single Pitch Error
PitchHelical
Single Pitch Error
PitchStraight
Single Pitch Error
3. Quality Policy of APEX Rack
26
Declaration of Tolerance / Total Pitch Error (per 1000mm)
Total Pitch Error
Total Pitch
Total Pitch Error
Total Pitch
The 1st Tooth The last Tooth
3. Quality Policy of APEX Rack
27
Declaration of Tolerance
Example: Application in CNC Machine Tools or other high
precision transmission system
Only with high precision rack, it is possible to do a compensation
or correction during the machining process.
About the precision, the other rack manufacturers in the world
declare only Total Pitch Error and rarely Single Pitch Error.
They never declare clearly all about :
The Tolerance of the Dimensions and Geometry
The defined Straightness, Parallelism and Perpendicularit
The Helical Angle and Pressure Angle with Tolerance
Surface Roughness of the Teeth
Defined Hardness and Thickness of the Hardened Layer
on the Teeth.
3. Quality Policy of APEX Rack
Mn ≦ 4 Scanning Induction Hardening
Induction
Annealing
4. Introduction to Induction Hardening
Heating with induction coiler
hanging over the rack, temperature
up to 900°~1000°C, then rapid
cooling (quenched) by water shower.
Heating with ~300°C, to adjust
the hardness and to optimise the
metallographic structure.
28
29
Mn ≦ 4 Scanning Induction Hardening
Heating from above
Pitch line
Hardness
Hard
Soft
Gear coupling area with
pinion must be hard !
4. Introduction to Induction Hardening
30
Mn ≦ 4 Scanning Induction Hardening
Induction
Heat treatment Surface Effective
Hardness (HV) 550 ± 40 440 ± 32
For each Module No., the L is well
defined as the lower limit of the
Effective Hardness.
L
L
Hardness Curve
Upper limit Lower limit
4. Introduction to Induction Hardening
Eng. Drawing
Measurement
31
Mn ≦ 4 Scanning Induction Hardening
Thickness of the hardened layer not enough.
Unqualified !!
Pitch line
4. Introduction to Induction Hardening
32
Unqualified Qualified
Cross-Section
Mn ≦ 4 Scanning Induction Hardening
Gear coupling area
Effective hardness
4. Introduction to Induction Hardening
33
In order to achieve the thickness of hardened layer, the heat must be induced
into the depth of material. By heating from above (scanning), the top and
surface of teeth can be overheated, even melded.
Decarburization can happen and the metal structure becomes porous.
Porous !
4. Introduction to Induction Hardening
34
Metallographic Analysis of Decarburization
Standard Overheated Coarse Grains
Brittle / Crisp
Reduced Strength
Easy damage on the
tooth profile or even
break up.
4. Introduction to Induction Hardening
35
Mn ≧ 5 Contour Induction Hardening (Tooth-by-Tooth)
4. Introduction to Induction Hardening
36
induction
Heat treatment Surface Effective
Hardness (HV) 550 ± 40 440 ± 32
Mn ≧ 5 Contour Induction Hardening (Tooth-by-Tooth)
LLeft
LRight
Hardness Curve
H
L
4. Introduction to Induction Hardening
37
Cross-Section
Mn ≧ 5 Contour Induction Hardening (Tooth-by-Tooth)
> 80% area Effective hardness
4. Introduction to Induction Hardening
38
Carburized Induction
After Carburizing After Carburizing
and Induction
Induction
4. Introduction to Induction Hardening
39
Carburized Induction
(Before Annealing)
LLeft
LRight
Hardness Curve
4. Introduction to Induction Hardening
After Carburizing
and Induction
H
L
40
Symmetry after Induction Hardening
and Teeth Grinding
Carburizing and Induction Contour Induction
4. Introduction to Induction Hardening
41
Bad Example !
Bad
induction
hardening
Bad induction
hardening and bad
teeth grinding.
Symmetry after Induction Hardening
and Teeth Grinding
4. Introduction to Induction Hardening
Carburizing and Induction Contour Induction
42
5. Specification of APEX Rack
Heat-Treatment: Case-Hardening / Carburizing / Normalizing /
Annealing / Induction / Q&T / Solution
Teeth and Sides: Milling / Grinding / Polishing
Material: Carbon Steel / Alloy Steel / Q&T Steel / Stainless Steel
Coating: Nickel Plating / Phosphate Film / Blackening
Quality: Q4 / Q5H / Q5 / Q6 / Q6M / Q8H / Q8 / Q9 / Q10
43
5. Specification of APEX Rack
No international Rack Standard in the world
No DIN, only Quality !!
Very rack maker sets his own Quality standard.
Q6 of Maker A = Q6 of Maker B ??
APEX design and produce the rack according to the
DIN Standard of Gears and Pinions !
44
Specification of APEX Q8
APEX
Material Carbon Steel
Heat-Treatment Normalizing
Teeth Milled
All Sides Milled
Total Pitch Error
(mm/1000mm)
0.065 mm ~ 0.09 mm
(M1) (M12)
Carbon Steel with Normalizing Heat-Treatment
Finer Homogenous Grains
Outlet of Internal Tension
Higher Strength
Higher Feed Force / Torque
5. Specification of APEX Rack
45
APEX Q8 vs. ATLANTA Q9 *
APEX ATLANTA
Material Carbon Steel S45C
Heat-Treatment Normalizing None
Teeth Milled Milled
All Sides Milled None (Bright Steel)
Total Pitch Error
(mm/1000mm)
0.065 mm ~ 0.09 mm
(M1) (M12)
≦ 0.150 mm
(M=?)
Advantage ** Higher Torque and Feed
Force, Higher Accuracy
5. Specification of APEX Rack
= Cold Drawn of metal bar.
Internal tensions remained in material, leading to
deformation. Morover, no machining on side-
surfaces bad accuracy.
* Comparison made basing on production
process, not necessarily on quality Q.
** Comparison made ONLY for Total Pitch
Error. No other ATLANTA data could be
found for comparison.
46
APEX ATLANTA
Material Carbon Steel S45C / 42CrMo4
Heat-Treatment Normalizing Induction / Q&T
Teeth Milled Ground / Milled
All Sides Milled None (both Bright Steel)
Total Pitch Error
(mm/1000mm)
0.065 mm ~ 0.09 mm
(M1) (M12)
0.060 mm / 0.100 mm
Advantage Higher accuracy on teeth, but
worse on the sides.
Higher wearing resistance
5. Specification of APEX Rack
APEX Q8 vs. ATLANTA Q8 (Teeth hardened & ground)
47
Specification of APEX Q8H
APEX
Material Alloy Q&T Steel
Heat-Treatment Quenched and Tempered
Teeth Milled
All Sides Milled
Total Pitch Error
(mm/1000mm)
0.065 mm ~ 0.09 mm
(M1) (M12)
Advantage
Application High Rigidity
For without Back-Support
5. Specification of APEX Rack
With Back-Support
Without Back-Support
48
APEX ATLANTA
Material Alloy Q&T Steel S45C / 42CrMo4
Heat-Treatment Quenched and Tempered Induction / Q&T
Teeth Milled Ground / Milled
All Sides Milled None (both Bright Steel)
Total Pitch Error
(mm/1000mm)
0.065 mm ~ 0.09 mm
(M1) (M12)
0.060 mm / 0.100 mm
Advantage Higher accuracy
5. Specification of APEX Rack
APEX Q8H vs. ATLANTA Q8 (42CrMo4)
49
Specification of APEX Q10
APEX
Material Carbon Steel
Heat-Treatment Induction on Teeth (of Q8)
Teeth Milled
All Sides Milled
Total Pitch Error
(mm/1000mm)
0.146 mm ~ 0.202 mm
(M1) (M12)
Advantage Higher wearing resistance
Lower accuracy
5. Specification of APEX Rack
50
APEX Q10 vs. ATLANTA Q10
APEX ATLANTA
Material Carbon Steel S45C
Heat-Treatment Induction on Teeth Induction on Teeth
Teeth Milled Milled
All Sides Milled Milled
Total Pitch Error
(mm/1000mm)
0.146 mm ~ 0.202 mm
(M1) (M12)
0.200 mm
Advantage Higher accuracy
5. Specification of APEX Rack
51
APEX Q9 vs. ATLANTA Q9
APEX ATLANTA
Material Stainless S45C
Heat-Treatment Solution None
Teeth Milled Milled
All Sides Milled None (Bright Steel)
Total Pitch Error
(mm/1000mm)
0.091 mm ~ 0.109 mm
(M1) (M6)
≦ 0.150 mm
(M=?)
Advantage Higher Accuracy
(even by Stainless Steel
which is harder to machine)
5. Specification of APEX Rack
Specification of APEX Q6M
APEX Rack Q6M
Q6M : M = Milling on the 3 sides of rack
Q6M = Quality 6 Q7 = Quality 7
Total Pitch Error 0.033 mm ~ 0.046 mm
(M2) (M10)
0.047 mm ~ 0.060 mm
(M1) (M12)
Milling vs. Grinding Same dimension, different surface roughness
All sides milled FIXED on the machine-bed, no movement.
Roughness not important!
52
53
Specification of APEX Q6M
APEX
Material Carbon Steel
Heat-Treatment Induction on Teeth
Teeth Ground
All Sides Milled
Total Pitch Error
(mm/1000mm)
0.033 mm ~ 0.046 mm
(M2) (M10)
Advantage Higher teeth precision,
Higher wearing resistance
5. Specification of APEX Rack
54
APEX Q6M vs. ATLANTA Q8 (Teeth hardened & ground)
APEX ATLANTA
Material Carbon Steel S45C / 42CrMo4
Heat-Treatment Induction on Teeth Induction / Q&T
Teeth Ground Ground / Milled
All Sides Milled None (both Bright Steel)
Total Pitch Error
(mm/1000mm)
0.033 mm ~ 0.046 mm
(M2) (M10)
0.060 mm / 0.100 mm
Advantage Higher accuracy
5. Specification of APEX Rack
55
APEX Q6M vs. ATLANTA Q7
APEX ATLANTA
Material Carbon Steel S45C
Heat-Treatment Induction on Teeth Induction on Teeth
Teeth Ground Ground
All Sides Milled Ground
Total Pitch Error
(mm/1000mm)
0.033 mm ~ 0.046 mm
(M2) (M10)
0.052 mm
Advantage
5. Specification of APEX Rack
The same material and
same process like by Q6
Unqualified Q6 Q7 ??
56
Specification of APEX Q6
APEX
Material Carbon Steel
Heat-Treatment Induction on Teeth
Teeth Ground
All Sides Ground
Total Pitch Error
(mm/1000mm)
0.033 mm ~ 0.046 mm
(M1) (M12)
Advantage
5. Specification of APEX Rack
57
APEX Q6 vs. ATLANTA Q6
APEX ATLANTA
Material Carbon Steel 16MnCr5 / S45C
Heat-Treatment Induction on Teeth Carburized & Induction
/ Induction
Teeth Ground Ground
All Sides Ground Ground
Total Pitch Error
(mm/1000mm)
0.033 mm ~ 0.046 mm
(M1) (M12)
0.036 mm
(M2~M4 / M1.5~M12)
Advantage
5. Specification of APEX Rack
58
Specification of APEX Q5
APEX
Material Carbon Steel Alloy Steel
Heat-Treatment Induction on Teeth Carburized & Induction
Teeth Ground Ground
All Sides Ground Ground
Total Pitch Error
(mm/1000mm)
0.028 mm ~ 0.033 mm
(M4) (M12)
0.024 mm ~ 0.026 mm
(M2) (M3)
Advantage Rigidity :
Alloy Steel > Carbon Steel
5. Specification of APEX Rack
59
APEX Q5 (Alloy Steel) vs. ATLANTA Q6 (16MrCr5)
APEX ATLANTA
Material Alloy Steel 16MnCr5 / S45C
Heat-Treatment Carburized & Induction Carburized & Induction
Teeth Ground Ground
All Sides Ground Ground
Total Pitch Error
(mm/1000mm)
0.024 mm / 0.026 mm
(M2) (M3)
0.036 mm
(M2~M4)
Advantage Higher Accuracy
5. Specification of APEX Rack
60
Specification of APEX Q5H, “Heavy Duty”
APEX
Material Alloy Steel
Heat-Treatment Case Hardening
Teeth Ground
All Sides Ground
Total Pitch Error
(mm/1000mm)
0.024 mm ~ 0.031 mm
(M2) (M10)
Advantage
Application High Rigidity
For without Back-Support
5. Specification of APEX Rack
With Back-Support
Without Back-Support
61
APEX Q5H Heavy Duty vs. ATLANTA Q5 Strong Line
APEX ATLANTA
Material Alloy Steel 16MnCr5
Heat-Treatment Case Hardening Case Hardening
Teeth Ground Ground
All Sides Ground Ground
Total Pitch Error
(mm/1000mm)
0.024 mm ~ 0.031 mm
(M2) (M10)
0.026 mm
(M3~M6)
Advantage Wide Rang of Module No.
5. Specification of APEX Rack
62
APEX
Material Carbon Steel
Heat-Treatment Induction on Teeth
Teeth Ground
All Sides Ground
Total Pitch Error
(mm/1000mm)
0.02 mm ~ 0.023 mm
(M5) (M12)
Application High-End CNC /
Measurement Equipment
Specification of APEX Q4
5. Specification of APEX Rack
63
APEX Q4 vs. ATLANTA Q3 (Q4 in old catalog)
APEX ATLANTA
Material Carbon Steel S45C
Heat-Treatment Induction on Teeth Induction on Teeth
Teeth Ground Ground
All Sides Ground Ground
Total Pitch Error
(mm/1000mm)
0.02 mm ~ 0.023 mm
(M5) (M12)
0.012 mm
(same as Q4 in old Catalog)
Advantage Higher Accuracy (?)
Corresponding to DIN Standard of Gears !!
5. Specification of APEX Rack
64
About the Feed Force of the Rack Teeth
5. Specification of APEX Rack
Basing on Material and Heat-Treatment :
Rigidity of 〔Alloy Steel + Case-Hardening〕
~ 〔Alloy Steel + Carburized & Induction〕
~ 〔Carbon Steel + Induction〕
>>〔Carbon Steel + Normalizing〕
Basing on Quality :
Q4 >> Q5 >> Q6 >> Q7 >> Q8 > Q9 >> Q10*
(* If the heat-treatment also considered, Q10 >> Q8, Q9)
Basing on Teeth Angle :
Helical >> Straight
Basing on Module-No. (Mn) :
Larger Mn >> Smaller Mn
65
5. Specification of APEX Rack
About the Noise Level (dB) of the Rack
Basing on Teeth Machining :
dB Value of〔Ground Teeth〕<<〔Milled Teeth〕
Basing on Teeth Angle :
Helical << Straight
Basing on Quality :
Q4 << Q5 << Q6 << Q7 << Q8 << Q9 << Q10
Basing on Module-No. :
Smaller Mn << Larger Mn
66
About the Wearing Resistance of the Rack
5. Specification of APEX Rack
Basing on Material and Heat-Treatment :
Wearing Resistance of
〔Alloy Steel + Case-Hardening〕
~ 〔Alloy Steel + Carburized and Induction〕
~ 〔Carbon Steel + Induction〕
>> 〔Carbon Steel + Normalizing〕
Basing on Quality :
Q4 >> Q5 >> Q6 >> Q7 >> Q10 >> Q8 ~ Q9
Basing on Teeth Angle :
Straight >> Helical (due to less teeth surface)
67
Measurement Report for Q4 / Q5 / Q5H
2016.08.31
5. Specification of APEX Rack
GKRDSF
GKRDSF
68
4° Chamfering of APEX Rack (Q6↑)
4° To Avoid
Interference bw.
rack and machine-
bed due to thermal
deformation
Patented !
5. Specification of APEX Rack
69
Selection of Rack
Module No.?
Quality ?
Teeth Induction hardened and Ground?
Torque / Feed-Force ?
Total Pitch Error ?
Backlash ?
Rack is to select in combination with Pinion !!
Considering: Torque / Feed Force / Backlash / Noise…
5. Specification of APEX Rack
70
APEX Rack Catalog
5. Specification of APEX Rack
71
APEX Rack Order Code
5. Specification of APEX Rack
72
APEX Rack Order Code
5. Specification of APEX Rack
Customization
Material
Heat-Treatment
Module-No.
Special Teeth
Teeth Hardening
Quality
Cross-Section
Length
Screw-Holes
Special Form
5. Specification of APEX Rack
73
Customer drawing
APEX drawing for confirm
Customer should accept
± 10% of order volume
Customization
Material
Heat-Treatment
Module-No.
Special Teeth
Teeth Hardening
Quality
Cross-Section
Length
Screw-Holes
Special Form
5. Specification of APEX Rack
74
75
6. General Instruction of APEX Pinion
APEX Pinion Series
A : Curvic Plate B : Welded Plate C : Teeth Plate C : Teeth Plate with Flange
D : DIN 5480 E / F : Keyway F : Keyway with Shrink-Disc
76
Electron Beam Welding
APEX Pinion Series B “Welded Plate“ (EN ISO 9409-1-A)
6. General Instruction of APEX Pinion
77
APEX Pinion Series C “Teeth Plate“ (EN ISO 9409-1-A)
6. General Instruction of APEX Pinion
78
Convex Teeth
Concave Teeth
APEX Pinion Series A “Curvic Plate“
Patented !!
6. General Instruction of APEX Pinion
1.
2.
79
Curvic-Coupling
APEX Pinion Series A “Curvic Plate“
6. General Instruction of APEX Pinion
80
All-Teeth-Coupling between pinion and gearbox
Zero backlash
Automatical concentricity
High torque transmission
The Round-Out of the gearbox-pinion-set can be adjusted
by switching the curvic positions.
Quick assembly and disassembly / replacement
More suitable pinion teeth-no. can be chosen.
Advantages of Curvic Coupling
6. General Instruction of APEX Pinion
APEX Pinion Series A “Curvic Plate“
81
6. General Instruction of APEX Pinion
Advantages of Curvic Coupling
APEX Pinion Series A “Curvic Plate“
*Because of possible interference
bw. pinion-teeth and screw-holes.
Teeth-No. ≧ N Teeth-No. ≦ n*
82
Teeth-No. ≧ N Teeth-No. ≦ n
6. General Instruction of APEX Pinion
With Curvic Plate there is a
wider rang of teeth no. Z
applicable!
Also available: n ≦ Z ≦ N
Advantages of Curvic Coupling
APEX Pinion Series A “Curvic Plate“
83
6. General Instruction of APEX Pinion
APEX Pinion Series A “Curvic Plate“ vs. Teeth Plate with Flange
Torque is limited by
the screw strength
High Torque-
transmission
Same PCD
84
DIN5480 Interface
APEX Pinion Series D “Spline“ (DIN 5480)
6. General Instruction of APEX Pinion
85
APEX Pinion Series D “Spline“ (DIN 5480)
6. General Instruction of APEX Pinion
Production process of internal DIN 5480 teeth
ATLANTA Carburized Induction (based on APEX analyze)
APEX Case Hardening
High rigidity, high-precision
(Quality of internal DIN 5480 teeth = DIN 7)
Good concentricity and good round-out
when applied to the gearbox.
86
APEX Pinion Series E “Keyway“
Keyway / Key
6. General Instruction of APEX Pinion
With Shrink Disc
87
The Teeth Top and Profile of APEX pinions are ground simultaneously !!
Round-out of pinion on the gearbox (basing on teeth-profile)
== Round-out of pinion measured on the teeth top
Round-out of APEX pinion can be adjusted via Teeth Top directly.
6. General Instruction of APEX Pinion
88
Pinion APEX ATLANTA
Material Alloy Steel 16MnCr5
Heat-Treatment Case Hardening Case Hardening
Teeth Ground Ground
Welded Plate
Curvic Plate
Teeth Plate
Spline (DIN 5480 )
Keyway
DIN 4
DIN 4
DIN 4
DIN 5*
DIN 5
DIN 5
--
DIN 5
DIN 5**
DIN 6
6. General Instruction of APEX Pinion
* : Quality of internal DIN 5480 teeth = DIN 7
** : Heat-Treatment should be Carburized Induction.
89
6. General Instruction of APEX Pinion
APEX Pinion Order Code
Selection of Pinion / Big or Small ??
7. Selection of Rack and Pinion
90
91
Mn = 3 Mn = 3
Z = 12 Z = 40
Torque = Radius x Force
r
R
f F
l L
Selection of Pinion / Big or Small ??
Torque Transmission is the most important !!
7. Selection of Rack and Pinion
92
Small Pinion / Less Teeth
Low Torque / Low Speed
With low ratio (1 Stg.) Gearbox
Low Cost
High Cycling Frequency
High Wearing / Short Life-Time
More sensitive to Vibration
Big Pinion / More Teeth
Large Torque / High Speed
With high ratio Gearbox (2 Stg. ↑)
Higher Cost
Low Cycling Frequency
Less Wearing / Longer Life-Time
Backlash / Inaccuracy can be enlarged by bigger Pinion Radius
More smooth running
Selection of Pinion / Big or Small ??
7. Selection of Rack and Pinion
93
7. Selection of Rack and Pinion
Feed Force, Torque / Curvic Plate
94
APEX recommends: ~ 20 Teeth !!
But ATLANTA and Co. said, smaller (z=12~14) better !
Pinion Quality = Rack Quality
Selection of Pinion / Big or Small ??
Refer to pages
75, 81~83, 91~93!
7. Selection of Rack and Pinion
95
Selection of Rack & Pinion
7. Selection of Rack and Pinion
Calculation of
Torque or Feed-Force
Choose the required
Quality
With or without
Back-Support ?
Life-Time
Environment
Noise?
Stainless? Coating?
Also refer to page
64~66, 94.
96
Selection of Rack & Pinion
7. Selection of Rack and Pinion
Material
Heat-Treeatment
Module No.
Width of Teeth (Rack and Pinion)
Quality of Rack
Teeth No. of Pinion
Helical or Straight
Pinion (fixing) on the Gearbox
Rack fixing on the Machine bed
APEX HQ
Customer
Also refer to page
64~66, 94.
97
Selection of Rack & Pinion
7. Selection of Rack and Pinion
Also refer to page
64~66, 94.
Calculation of Torque (Feed Force) of Application
Mass, Acceleration/Speed, Motor & Gearbox
Choose the suitable Rack-Pinion Combination
based on the Torque of Curvic Plate
Example: Torque = 450 Nm
Selection basing on Feed Force / Torque
7. Selection of Rack and Pinion
98
99
Selection of Rack & Pinion
7. Selection of Rack and Pinion
Also refer to page
64~66, 94.
Calculation of Torque (Feed Force) of Application
Mass, Acceleration/Speed, Motor & Gearbox
Choose the suitable Rack-Pinion Combination
based on the Torque of Curvic Plate
Example: Torque = 450 Nm
M3+Z17+Q6 or
M3+Z18+Q5 or
M3+Z20+Q6M or
M4+Z18+Q10 or
M4+Z19+Q8 would be suitable!
100
Calculation of Torque (Feed Force) of Application
Mass, Acceleration/Speed, Motor & Gearbox
Choose the suitable Rack-Pinion Combination
based on the Torque of Curvic Plate
Example: Torque = 450 Nm
M3+Z17+Q6 or M3+Z18+Q5 or M3+Z20+Q6M or
M4+Z18+Q10 or M4+Z19+Q8 would be suitable!
Which Type of Pinion?
High Accuracy (with/without Linear Scale)?
Wearing Resistance? (Low Cycling Rate?)
Without Back-Support? (Q8H / Q5H?)
Total Cost (Rack + Pinion + Gearbox + Motor)
Selection of Rack & Pinion
7. Selection of Rack and Pinion
Also refer to page
62~64, 91.
101
Selection basing on Feed Force / Torque
7. Selection of Rack and Pinion
No Back-Support
By APEX All in One Hand !!
Quality Guarantee for Customer !!
Gearbox with Rack & Pinion
7. Selection of Rack and Pinion
102
Q6 = Q6 ?? Marketing : Price vs. Quality
Low margin product Laaaaarge Order Discount
Lead Time = ? No screw-holes?
Large oder piece-no. / Stock should be considered
(2 years conservation guarantee in original APEX package)
Package and transport from APEX to APEX Agents (Sea freight !)
Local transport from APEX Agents to customer
Open Issues to APEX Agents
7. Selection of Rack and Pinion
103
APEX DYNAMICS, INC. / TAIWAN