Two high-volume gear production cells grace the shop floor at Delta Research Corporation in Livonia, Michigan. Thanks to lean manufacturing, these cells have never shipped a defective part to a customer since they were developed over three years ago.
As is well known in involute gearing, “perfect” involute gears never work perfectly in the real world.
Flank modifications are often made to overcome the influences of errors coming from manufacturing and assembly processes as well as deflections of the system. The same discipline applies to hypoid gears.
A computational fluid dynamics (CFD) method is adapted, validated and applied to spinning gear systems with emphasis on predicting windage losses.
Several spur gears and a disc are studied. The CFD simulations return good agreement with measured windage power loss.
On the production floor at Knechtel,
food scientists, chemists and engineers
take part in Willy Wonka-like experiments in search of the perfect piece of candy.