Designing complex gauges for inspection of keyway joint parts when repairing reduction gears

A significant advantage of using complex gauges for inspecting the geometric parameters of keyway joint components is the substantial reduction in inspection labor intensity. However, the primary challenge in their application lies in designing a set comprising a complex plug gauge and a prism gauge, accounting for the standardized values of the controlled parameters of the joint, as well as ensuring their regular reproduction as wear occurs. The study aimed to design a set of complex gauges for inspecting the dimensions and geometric parameters of a shaft with a keyway and a coupling bore with a keyway. The gauges were required to ensure the assemblability of the shaft connection with a chain coupling installed on the universal reduction gear N090.40.000 manufactured by the Mosselmash plant. The theoretical foundation of the research included regulatory documents governing tolerance requirements for the controlled parameters and the dimensions of complex gauges. The methodology employed an integrated approach that included analysis of technical documentation, computational and theoretical methods, and gauge design. The calculations established that, with manufacturing tolerance taken into account, the thickness of the control key in both the plug gauge and the prism gauge is 13.995⁻⁰·⁰⁰⁵ mm. The plug gauge for controlling the minimum internal dimension of the coupling measures 49.995⁻⁰·⁰⁴ mm. The go plug gauge, accounting for the height of the control key, measures 53.5⁻⁰·²⁵ mm. For controlling the limit dimensions of worn gauges, the minimum limit size of the control key thickness for both the plug gauge and the prism gauge is 13.985 mm, while the minimum limit size of the diameter of the worn plug gauge is 49.982 mm. Inspection during verification (calibration) of the established dimensions of the plug gauge and the prism gauge in service will timely detect their wear. The use of the designed set of complex gauges will ensure high measurement accuracy and reliable assessment of the assemblability of the keyway joint between the reduction gear shaft and the chain coupling. The study results are applicable in mechanical engineering for the technical inspection of keyway joints.

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