Abstract: An internal gear and cap assembly includes a gear having a base that extends about an axis between a first and second end. The first end defines a groove that extends to a floor and the groove surrounds the axis. Teeth extend from the base. A lip extends from the first end and also surrounds the axis. A cap has a flange that is inserted into the groove. The lip is deformed toward the groove such that material from the lip flows to trap the flange between the lip and the floor of the groove to retain the cap to the gear in the axial direction. Slots may be defined in the flange such that the material from the lip flows into the slots to provide a key-lock between the cap and the gear to prevent rotation of the cap relative to the gear about the axis.

Abstract: A system and method for forming a feature on an inner surface of a gear includes a sensor for sensing the position of a feature on the gear, a cutting station having a cutting tool for forming the feature on the inner surface of the gear, and a controller. The controller is operable to determine an amount of rotation necessary to rotate either the gear or the cutting tool such that the feature on the inner surface of the gear is formed at a desired orientation relative to the feature on the outer surface of the gear.

Abstract: An internal gear and cap assembly includes a gear having a base that extends about an axis between a first and second end. The first end defines a groove that extends to a floor and the groove surrounds the axis. Teeth extend from the base. A lip extends from the first end and also surrounds the axis. A cap has a flange that is inserted into the groove. The lip is deformed toward the groove such that material from the lip flows to trap the flange between the lip and the floor of the groove to retain the cap to the gear in the axial direction. Slots may be defined in the flange such that the material from the lip flows into the slots to provide a key-lock between the cap and the gear to prevent rotation of the cap relative to the gear about the axis.

Abstract: An internal gear and cap assembly includes a gear having a base that extends about an axis between a first and second end. The first end defines a groove that extends to a floor and the groove surrounds the axis. Teeth extend from the base. A lip extends from the first end and also surrounds the axis. A cap has a flange that is inserted into the groove. The lip is deformed toward the groove such that material from the lip flows to trap the flange between the lip and the floor of the groove to retain the cap to the gear in the axial direction. Slots may be defined in the flange such that the material from the lip flows into the slots to provide a key-lock between the cap and the gear to prevent rotation of the cap relative to the gear about the axis.

Abstract: A method for machining a surface on a workpiece having a member extending perpendicularly to the surface includes determining a position of a tool, determining a position of the workpiece, positioning at least one of the workpiece and the tool to a predefined position, rotating the workpiece, and rotating the tool to a predefined rotational speed. The predefined rotational speed synchronizes the rotation of the tool with the rotation of the workpiece in order to avoid unwanted contact between the tool and the member. The method includes the steps of translating at least one of the tool and the workpiece in a direction parallel to an axis defined by the workpiece, removing material from a first portion of the workpiece, translating at least one of the tool and the workpiece in a direction perpendicular to the axis of the workpiece, and removing material from a second portion of the workpiece.

Abstract: A system and method for manufacturing an internal gear is provided. A carrier is used to transport a gear blank having a first predefined pitch diameter to face width ratio. A forming tool is used for forming a plurality of teeth on the gear blank and provides other gear and spline forming operations. A furnace heats the gear having the plurality of teeth formed thereon to a predefined temperature for a predefined length of time to form a carburized gear. Finally, a cutting tool is provided to cut the gear at predefined location along its face to form at least two separate gears each having a second and third pitch diameter to face width ratios.

Abstract: A method for manufacturing a gear having a plurality of gear teeth includes the steps of: determining a desired finished gear characteristic, determining a reference feature on the gear to establish an origin on the gear, determining an unfinished dimension of a surface of at least one of the plurality of gear teeth relative to the origin, estimating a desired stock removal that will achieve the desired finished gear characteristic, finishing the gear using a finishing tool, determining a finished dimension of the surface of the at least one of the plurality of gear teeth relative to the origin, determining actual stock removal by comparing the unfinished dimension with the finished dimension, and comparing the actual stock removal with the desired stock removal.

Abstract: A method for machining a surface on a workpiece having a member extending perpendicularly to the surface includes determining a position of a tool, determining a position of the workpiece, positioning at least one of the workpiece and the tool to a predefined position, rotating the workpiece, and rotating the tool to a predefined rotational speed. The predefined rotational speed synchronizes the rotation of the tool with the rotation of the workpiece in order to avoid unwanted contact between the tool and the member. The method includes the steps of translating at least one of the tool and the workpiece in a direction parallel to an axis defined by the workpiece, removing material from a first portion of the workpiece, translating at least one of the tool and the workpiece in a direction perpendicular to the axis of the workpiece, and removing material from a second portion of the workpiece.

Abstract: A device for centering a work piece with respect to a centerline of a tool includes a radially-stationary component rigidly secured with respect to the tool such that the radially-stationary component and the tool are concentric. A biasing mechanism is biased away from the radially-stationary component to apply substantially equally-distributed radial force at a periphery of the work piece to thereby center the work piece with respect to the tool. A method of broaching a work piece having an inner and an outer diameter includes machining the outer diameter and then applying circumferentially-distributed radial force to the inner diameter or the outer diameter to thereby center the work piece with respect to a broach tool. After the applying step, the method includes broaching the inner diameter of the work piece using the broach tool.

Abstract: An internal gear and cap assembly includes a gear having a base that extends about an axis between a first and second end. The first end defines a groove that extends to a floor and the groove surrounds the axis. Teeth extend from the base. A lip extends from the first end and also surrounds the axis. A cap has a flange that is inserted into the groove. The lip is deformed toward the groove such that material from the lip flows to trap the flange between the lip and the floor of the groove to retain the cap to the gear in the axial direction. Slots may be defined in the flange such that the material from the lip flows into the slots to provide a key-lock between the cap and the gear to prevent rotation of the cap relative to the gear about the axis.

Abstract: An apparatus for retaining a bearing member within a bore defined by a gear member is provided. The apparatus includes an outer bearing race defining at least one radially extending notch. A tab portion formed on the gear member and extending generally axially therefrom is also provided. The tab portion is deformable to be received within at least a portion of the at least one radially extending notch. The tab portion is operable to limit axial and rotational movement of the outer bearing race within the bore when the tab portion is deformed. A method of retaining the bearing member within the gear member is also provided.

Abstract: A system and method for forming a feature on an inner surface of a gear includes a sensor for sensing the position of a feature on the gear, a cutting station having a cutting tool for forming the feature on the inner surface of the gear, and a controller. The controller is operable to determine an amount of rotation necessary to rotate either the gear or the cutting tool such that the feature on the inner surface of the gear is formed at a desired orientation relative to the feature on the outer surface of the gear.

Abstract: A device for centering a work piece with respect to a centerline of a tool includes a radially-stationary component rigidly secured with respect to the tool such that the radially-stationary component and the tool are concentric. A biasing mechanism is biased away from the radially-stationary component to apply substantially equally-distributed radial force at a periphery of the work piece to thereby center the work piece with respect to the tool. A method of broaching a work piece having an inner and an outer diameter includes machining the outer diameter and then applying circumferentially-distributed radial force to the inner diameter or the outer diameter to thereby center the work piece with respect to a broach tool. After the applying step, the method includes broaching the inner diameter of the work piece using the broach tool.

Abstract: A system and method for manufacturing an internal gear is provided. A carrier is used to transport a gear blank having a first predefined pitch diameter to face width ratio. A forming tool is used for forming a plurality of teeth on the gear blank and provides other gear and spline forming operations. A furnace heats the gear having the plurality of teeth formed thereon to a predefined temperature for a predefined length of time to form a carburized gear. Finally, a cutting tool is provided to cut the gear at predefined location along its face to form at least two separate gears each having a second and third pitch diameter to face width ratios.

Abstract: The present invention provides a hobbing machine. The hobbing machine includes a clamp fixture adapted to retain a gear blank. A motor is operatively connected to the clamp fixture and is configured to rotate the clamp fixture and the gear blank together at a predetermined speed. A rotatable cutter is translatable into engagement with the gear blank and is configured to cut the gear blank and thereby produce a plurality of gear teeth. A de-burring tool is translatable into engagement with the gear blank and is configured to remove burrs from the gear blank as the gear teeth are being cut. A motorized spindle is operatively connected to the de-burring tool, and is configured to power and rotate the de-burring tool at a predefined speed to optimize the removal of the burrs.

Abstract: The present invention provides a hobbing machine. The hobbing machine includes a clamp fixture adapted to retain a gear blank. A motor is operatively connected to the clamp fixture and is configured to rotate the clamp fixture and the gear blank together at a predetermined speed. A rotatable cutter is translatable into engagement with the gear blank and is configured to cut the gear blank and thereby produce a plurality of gear teeth. A de-burring tool is translatable into engagement with the gear blank and is configured to remove burrs from the gear blank as the gear teeth are being cut. A motorized spindle is operatively connected to the de-burring tool, and is configured to power and rotate the de-burring tool at a predefined speed to optimize the removal of the burrs.