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Isotropic Super Finishing of large gears

In view of the ever growing durability demands on gears used in large gearboxes, Osro and REM have jointly developed machines and Isotropic Super Finishing (ISF) processes, specifically tailored to improve the surface finish of large gears.

The machines used in the ISF Process are designed to cope with the extreme weight of these large components. OSF has a range of machines suitable for Isotropic Super Finishing gears weighing up to 2000 kgs. Pinions up to 1000 kgs and Inverse gears, (sometimes referred as the hollow wheels), up to 2000 kgs.

The Isotropic Super Finishing process uses the effective and proven REM ISF method of surface refinement to increase the wear resistance of the gears. The surface improvement of the gear flanks results in a reduction in grey staining and micro pitting. The improved surface finish generated by the ISF process produces an improved load carrying capacity, lubrication regime,(EHL), and consequently greatly reduced wear.

 

Isotropic Super Finishing of a pinion gear
Isotropic Super Finishing of a pinion gear
A large gear being measured
A large gear being measured
Large gear finishing machine
Large gear finishing machine
Before and after pinion gears
Before and after pinion gears
Large planet gear
Large planet gear

The benefits are:

  • Reduction of surface roughness

  • Improved load carrying capacity

  • Improvement of grey staining resistance

  • Elimination of running in wear

  • Improvement of scuffing load capacity

  • Improvement of micro-pitting resistance

  • Reduction in lubricant filtration maintenance

  • Lower operating costs

  • Lower operating temperatures

The advantages of the Process can be applied to all gears whatever the application. However, specifically planetary gearboxes having Low Speed - High Load operating regimes gain tremendous benefit from the Isotropic Super Finishing process, particularly when not only the Planets and the Sun wheel, but also the Inverse gear is superfinished.

The process is also suitable for gearboxes which suffer from extreme wear and have to be rebuilt. Experience has shown that Isotropic Super Finishing of the replacement new gears, prior to assembly, can produce an up to three-fold increase in life expectancy.

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Profilometer readings

Test results
Test results

Both OSF and Osro GmbH have worked closely with several universities to investigate the effect of Isotropic Super Finishing on gears. In particular the companies have been involved in two FVA projects, ( projects 286 III & 521) as well an investigation carried out by the RWTH Aachen to compare the effect of Isotropic Super Finishing and coatings. A diagram showing the results of these tests is shown below.


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