The Cost Reduction Design For Mixer Reducer Based On Equal-Strength And Low-Noise Theory

During designs of reducers, unequal strength among the gears, and failure probability of contacting strength differing from which of bending strength will both lead to strength losses. The research aims at how to reduce costs of all the one-input-double-output mixer reducers by example of XM-270 reducer in accordance with Equal-Strength Design Theory and Low Noise Design Concept, and we will sum up several methods and notices during design which can provide a high reference value for reducers of the same kind, mainly as the following:First, we will analyze the causes of noise generated and the noises caused by load changes, and research into the variation laws of total length of contacting line on meshing plane and how overlap contact ratio  change the total length of contacting line, then the overlap contact ratio εβ will be confirmed. Secondly, we will analyze the safety factors of contacting strength and bending strength of gears in XM-270 reducer, by the failure probability of the safety factors we can get a good solution for cost reduction, and calculate the gear parameters by the ideal value εβ aiming at equaling failure probability of contacting strength and bending strength and reducing the distribution factor of axial load, Finally we will precise adjustment of the value of εβ by the way of axial modification. Thirdly, we will design the reducer via the calculated parameters above and calculate intensities of gears, bearings, gear box, etc., with UG for gear box and ANSYS for Finite Element Analysis. Finally, we will give a cost account for the reducer, mainly containing costs of rough forging parts, rough casting parts and bearings.From the research we can conclude that when contacting ratio factor εβ=1, the total length of contacting line remains invariable during mesh, which can reduce the variation of load and meshing noises theoretically. According to Equal-Strength Design Theory, the cost for reducer manufacturing will be cut by 10% when the failure probabilities of contacting strength and bending strength is designed as 1/100.