0:14
When we talk about the engine in the
0:16
head, there is an image of large loud
0:18
parts, powerful turbine compressors. But
0:21
there is among them Sophie's presence.
0:23
We don't notice small modest. This is a
0:27
gear like this. But try to remove it and
0:29
the whole engine will go silent because
0:31
it is the gear that connects the
0:33
mechanism and allows all these steel
0:36
giants to work as one in this geometry.
0:38
The power, the precision and the meaning
0:41
of the whole system. Today we will find
0:45
why is this detail invisible to the eye,
0:48
the heart of the movement.
0:55
But this is only at a glance now. It
0:57
seems so simple because here we look and
1:00
everything seems easy and simple to us
1:02
at a glance but in fact it is far from
1:04
so simple because the modern development
1:06
of our moose and that is where our
1:08
science and mechanical engineering
1:10
allows us to lay very complex geometry
1:13
in the tooth wine itself. The level of
1:16
machine tool construction that exists
1:18
today allows this whole very complex
1:20
geometry to be embodied directly in
1:22
microns or even more than 10 microns.
1:25
Not all testers are responsible and
1:28
unique in the form. There are gears that
1:29
are simple workers. Although it is
1:31
probably still correct to say that in an
1:33
aircraft engine every detail, yes, it is
1:36
responsible. It is necessary. It has a
1:39
certain functionality. But
1:42
there are gears that simple workers are
1:45
ordinary simple to gear. But raised
1:48
points, they do not bear high load and
1:50
they are mainly used in outboard boxes
1:53
of units. For example, they don't have
1:55
any pump or rotation sensors. That's it.
2:01
The loads that other gears experience,
2:03
these are what we call the most which
2:05
are the most responsible manufacturers
2:07
which are responsible for the overall
2:10
reliability and operation of the entire
2:12
engine are the central bevel gear.
2:16
These are those gears that rotate at the
2:19
same speeds, experience almost the same
2:21
loads as the engine rotor itself. This
2:24
is the work of the Swift. We say that
2:26
they are the most they are the most
2:27
responsible. They have the highest
2:29
manufacturing requirements which are
2:34
somewhere even dozens. Next is micron.
2:37
And these are the same interesting
3:05
So, we figured out why a gear has
3:07
perfect geometry, but it's not born
3:09
perfect. Each tooth goes a long way from
3:11
rough metal to perfect shape. First,
3:13
there is rough processing. At this
3:15
stage, the metal first acquires the
3:17
consoles of the future part. Then heat
3:20
treatment of the metal strengthens,
3:22
hardens, and makes stable loads that
3:24
will experience 1,000 hours of work.
3:30
And finally, frequency processing is
3:32
practically a jewel stage where every
3:34
micron of shavings is a step towards the
3:36
efficient operation of the entire
3:39
But even the perfect gear is only half
3:41
the story because she has a partner and
3:44
together about her the perfect furry
3:52
Well, any six I have is a park in
3:54
Russia. That is any blank is some kind
3:56
of cylindrical blank. Yes, if we allow
4:01
or is it some kind of ring blank?
4:03
Therefore the main machining in general
4:05
is more precisely or all the processing
4:07
that is associated with the processing
4:09
of poly. This is rough turning. The
4:11
maximum removal of material is a blank.
4:14
Then heat treatment occurs which after
4:16
rough turning will lay down the basic
4:18
properties of the material which are
4:20
reported in the design documentation.
4:25
After this preliminary such basic heat
4:27
treatment is performed.
4:30
The halfhour processing which will
4:32
include various stages is embodied in
4:34
the drawing. These are various groups.
4:37
Half hour turning, preliminary turning,
4:39
then depending on the design, a
4:42
strengthening heat treatment can be
4:44
carried out which provides a high
4:46
hardness of the profile surface and then
4:48
the final treatment is already taking
4:53
Blinding this is considered a finishing
4:56
tennis treatment. 60% of all success in
4:59
the manufacturer of gears is heat
5:03
During heat treatment, the basic
5:05
properties materials that start the
5:07
design documentation are laid and high
5:10
hardness of the gear profile is also
5:13
ensured. If the heat treatment is
5:15
performed incorrectly or with a
5:17
deviation, it will no longer be possible
5:21
This will be considered however the
5:23
remaining 40% let's say this is the
5:26
finishing treatment of the blindness
5:28
operation which provides these very
5:30
micron and this is the accuracy that
5:33
lies in the documentation in the end
5:42
rough processing as I said yes this is
5:45
the processing in which the maximum
5:47
material is removed yes from the surface
5:49
of the work piece After rough
5:51
processing, the part acquires just
5:54
outlines or counters. What we see is the
5:57
drawings of frequent processing. Without
5:59
changing the outline of the part, the
6:01
part acquires its final shape the
6:03
geometric appearance that we see in the
6:05
design documentation.
6:07
Well, you can even give a clear example.
6:09
Yes, what is the difference between
6:10
rough processing and finishing? If we
6:12
need, for example, to paint a large wall
6:14
over the area, yes, we will most likely
6:17
choose some kind of broad script or
6:18
varia. Yes. What if we need to draw some
6:21
ornament or pattern? We will rather
6:23
choose the piston in the same way when
6:25
processing the session. Yes, of course,
6:28
you can starting from the work piece
6:30
produce it and grind it in the same way.
6:32
For example, on a lathe, try to catch
6:34
this micron. Yes, it's all the same, but
6:37
it's with a thin brush. Yes. Or a
6:40
roller. This is our tears. This is our
6:44
time. This is our nerve because it will
6:46
be very long through mechanical
6:49
engineering. This is called the economic
6:51
efficiency of processing or let's say
6:54
the labor intensity of manufacturing
6:56
part if it is very long in time and
6:59
takes away the strength of the worker.
7:00
Then the part will cost like painting
7:03
from the louver and such a product at
7:05
such a cost will be unprofitable and no
7:08
one will have a laptop.
7:18
The uniqueness of our gears, you their
7:21
identity. Each of those processes is
7:23
worked out and honed. Thanks to this, we
7:25
guarantee high reliability and close to
7:34
The highest accuracy is needed not only
7:36
for the sake of engine life. When the
7:38
six does not work, vibration is
7:40
perfectly reduced. And the less
7:41
vibration, the less noise, which means
7:43
the whole system works quieter and more
7:45
environmentally friendly.
7:54
Quality is formed from the system that
7:56
is implemented in the factory. Yes, this
7:59
system does not press quality. Control
8:02
is carried out from the purchase of
8:03
metal and ending at all stages of its
8:10
In the search accuracy regulated
8:13
precisely by the industry standards of
8:15
our aviation engineering, the designer
8:17
depending on the working conditions and
8:19
purpose of his gears precisely assigns
8:22
the degree of accuracy. Each degree of
8:24
accuracy is characterized by three
8:26
indicators. This is the norm of
8:27
kinematic accuracy. The standard of
8:30
tooth contact accuracy and the standard
8:33
of smoothness of operation. Each such
8:35
accuracy consists of certain complexity
8:38
and this is exactly what constitutes the
8:40
accuracy of the gear wheel.
8:46
An aircraft engine is a very highly
8:48
responsible product. In general, high
8:51
requirements are placed on it regarding
8:53
the strength reserve. So let's assume of
8:55
course that this is not a deviation.
8:57
This deviation from the design
8:59
documentation is correct. To do this you
9:01
will need to file a request for
9:03
rejection. The designer may perform some
9:06
calculations and make a final decision.
9:09
Is it possible to allow such a detail
9:13
for the product or impossible?
9:15
For instance, a few microns deviation
9:17
might be permissible.
9:19
It is possible that there will be some
9:21
noise and it is possible that the
9:23
uniformity of load distribution in the
9:25
pair of gears will shift. But again, I
9:28
repeat, nothing can happen. Here's for
9:30
our understanding. Most likely in case
9:33
of any defect or repair of the engine,
9:35
this gear which has a deviation but was
9:38
allowed for assembly will simply be
9:40
forcibly removed from operation since it
9:43
has some deviation. Well, a certain
9:45
number of hours which will be the record
9:50
If it functions, no issues should occur.
9:59
The most special thing is when you come
10:01
to the air show with children and when
10:04
your children say your dad did it, you
10:06
are happy and enjoy that everything is
10:12
The key is because I have something new
10:14
every day. Every day is a challenge
10:16
either production or technological
10:18
documentation or some new product
10:20
development that is every day is new and
10:40
From a cold workpiece to a unique pair
10:42
operating inside a massive engine, we've
10:45
completed the journey.
10:47
Every micron, every step, every check is
10:50
the contribution of hundreds of people.
10:52
But our part will take its place at the
10:54
heart of the engine and go straight to
