INDUSTRIAL

TRAINING
REPORT
2017
INDUSTRIAL TRAINING PRESENTATION

ON

GEAR MANUFACTURING

BY : VIMAL MAHESHWARI
CONTENTS

ABOUT THECOMPANY

SLECTION OF MATERIAL

GEAR MANUFACTURING PROCESS

ABOUT THE COMPANY
JRN ENGINEERING WORKS FARIDABAD
ESTABLISHED IN 2008.
BUSINESS TYPE :MANUFACTURER
PRODUCT MANUFACTURER : AUTOMATIC GEAR CHAIN
PRESENT CEO : MR.K.V.R NAIR
PRESNT HR :VINOD SINGH
DEPARTMENT : PRODUCTION,DESIGN,QUALITY CHEK
SECTION: MACHINE,PROGRAMING MACHINE

Selection of materials

The gear material should have the following properties:

High tensile strength to prevent failure against static loads
High endurance strength to withstand dynamic loads
Low coefficient of friction
Good manufacturability
Gear manufacture can be divided into two categories, forming and machining. Forming consists of direct
casting, molding, drawing, or extrusion of tooth forms in molten, powdered, or heat softened materials.
Machining involves roughing and finishing operations.
MACHINING
The bulk of power transmitting metal gears of machinery are produced by machining
process from cast, forged, or hot rolled blanks.Classification of machining processes. Roughing

processes include milling the tooth shape with formed cutters or generating the shape with a rack

cutter, a shaping cutter or a hob cutter

Despite its name, the roughing processes actually produce a smooth and accurate gear
tooth. Only for high precision and quiet running, the secondary finishing operation is justified at added cost.

Roughing processes:
Roughing process consists of forming, generation, shaping and hobbing processes. By this method gears are made

to an accuracy which is more than adequate for the slow speed

operations. These processes are dealt here.

Form milling:
Forming is sub-divided into milling by disc cutters and milling by end mill cutter which are having the shape of tooth
spacea separate
cutter. However, with 8 to 10 standard cutters, gears from 12 to 120 teeth can be cut with fair accuracy. Tooth is cut

one by one by plunging the rotating cutter into the blank as shown in fig .
Form milling by disc cutter:
The disc cutter shape conforms to the gear tooth space. Each gear needs a separate
.
cutter. However, with 8 to 10 standard cutters, gears from 12 to 120 teeth can be cut with fair accuracy. Tooth is cut

one by one by plunging the rotating cutter into the blank

 Form milling by disc cutter

Form milling by end mill cutter:

The end mill cutter shape conforms to tooth spacing. Each tooth is cut at a time and then
indexed for next tooth space for cutting. A set of 10 cutters will do for 12 to 120 teeth gears. It is suited for a

small volume production of low precision gears. The form milling by end mill cutter

Form milling by end mill cutter

To reduce costs, the same cutter is often used for the multiple-sized gears resulting in
profile errors for all but one number of teeth. Form milling method is the least accurate of all the
.
roughing methods.

Gear shaping:
Gear shaping used a cutting tool in the shape of a gear which is reciprocated axially across the gear blank to cut the teeth

while the blank rotates around the shaper tool. It is a true shape-generation process in which the gear-shaped tool cuts itself

into mesh with the

gear blank . The accuracy is good, but any errors in one tooth of the shaper cutter will be directly transferred to the gear.

Internal gears can be cut with this method as well.

Gear shaping
 Hobbing:
Hob teeth are shaped to match the tooth space and are interrupted with grooves to provide
cutting surfaces. It rotates about an axis normal to that of the gear blank, cutting into the rotating blank to

generate the teeth as shown in fig

Fig Hobbing

It is the most accurate of the roughing processes since no repositioning of tool or blank is required and each tooth is cut by

multiple hob-teeth, averaging out any tool errors. Excellent surface finish is achieved by this method and it is widely used for

production of gear
RACK GENERATION

In rack cutter the tooth shape is trapezoid and can be made easily. The hardened and sharpened rack is
reciprocated along the axis of the gear blank and fed into it while gear blank is being rotated so as to generate the
involute tooth on the gear blank.

The rack and gear blank must be periodically repositioned to complete the circumference. This introduces errors in
the tooth geometry making this method less accurate than shaping and hobbing.
Finishing Processes:
When high precision is required secondary operation can be performed to gears made by any of the above

roughing methods. Finishing operations typically removes little or no

material but improves dimensional accuracy, surface finish, and or hardness. The various finishing processes are

Shaving:
Shaving is similar to gear shaping, but uses accurate shaving tools to remove small
amounts of material from a roughed gear to correct profile errors and improve surface finish.

Shaving operation
External gear being shaved
-
Grinding:
In grinding, a contoured grinding wheel is run over machined surface of the gear teeth using computer control. With a

small amount of metal removal high surface finish is

obtained. Fig .shows grinding operations and dressing of the wheel.

(a) Grinding the flanks only, (b) Grinding root and flanks, (c) Grinding each

flank separately with twin grinding wheels and (d) Pantograph dressing of
the wheel

Grinding is used to correct the heat-treatment distortion in gears hardened after roughing.
Improvement in surface finish and error correction of earlier machining are added
advantages. Grinding operation for gears can be done by profile grinding or form grinding as shown in fig
 (a) (b)

(a) Maag zero pressure angle profile grinding and (b) Maag profile grinding

David Brown form grinding of worm threads

Burnishing:
In burnishing, a specially hardened gear is run over rough machined gear. The high forces
at the tooth interface cause plastic yielding of the gear tooth surface which improves finish and work hardens the surface

creating beneficial compressive residual stresses.

Lapping and Honing:
Lapping and honing both employ an abrasive-impregnated gear or gear-shaped tool that is run against the gear to abrade the

surface. In both cases, the abrasive tool drives the gear

in what amounts to an accelerated and controlled run-in to improve surface finish and the accuracy. Fig shows lapping

operation for bevel gears.

Special bevel gears being lapp

Latest Gear Shapers with CNC

A full CNC gear shaper incorporated the electronic gear box in the late eighties . Index change gear trains disappeared.
The elimination of gear trains also reduced and eliminated the inaccuracy caused by torsional windup of gearing system. DC/AC
servo motors drive the different axes. A total CNC gear shaper Fig. 4.10, has separate drives for :
1. Reciprocation with dead centre positioning - S axis.
2. Radial motion - X axis.
3. Rotation of cutter - D axis
4. Rotation of workgear - C axis
5. Stroke position - Z axis
6. Stroke length - V axis
7. Offset cutter head/workgear - Y axis
8. Relief angle for taper - B axis.

Each numerically controlled axis has its own independent drive as well as own position measuring system. CNC has simplified
the machine kinematics. However, CNC machine requires (a) high quality guide ways for precise positioning of the individual
axes by traversing without stick slip, and (b) thermal and mechanical stability for better and consistent accuracy..

The guiding motion to cutter spindle for attaining the desired lead on the gear being cut is still beyond CNC. Helical guides for
generating gears of varying leads are different and are to be changed manually. Japanese builders exhibited an attempt to
provide a CNC controlled guiding motion, where helix angle can be varied as desired for the cutter in use. However, the system
is yet to be perfected. Solution to this problem must be one of the important projects for research engineers working on gear
shaping.

Infeed Methods in Gear Shaping

Proper combination of rotary feed and radial infeed decides the type of chip formation and chip flow in gear shaping process. It
affects the tool wear rate and pattern as well as the
 Total CNC Gear Shaper

productivity of the operation. Some improved methods of infeed used in gear shaping are as follows:

1. Plunge feed during rotation

Radial infeed to the required depth to attain the desired size of the gear occurs simultaneously with rotation of the
cutter and workpiece. A comparatively short spiral path within the range of feeds is used. Triple flank chips, Fig. a,
are produced and chip crowding is critical.

2. Spiral infeed with constant radial feed

A continuous radial infeed at constant rate is applied till the required depth is reached. The shaping cycle requires
several work rotations to complete the operation. The long spiral path is attained by suitable combination of rotary
feeds with radial feeds. The machine must have capability to combine extremely high rates of rotary feed with
extremely low rates of radial infeed. The method produces thin chips at the tip and thick chips at the flank.Fig. b.
Chip formation and flow can be modified for better productivity and surface finish by varying the ratio of rotary to
radial feed.
Advantages of CNC Gear Shaping Machines

1.Improved accuracy
2.Reduce cycle time
3.Reduce setup time

1. Vertical or Horizontal

Generally, all modern gear shaping machines are with vertical cutter spindle. However, a machine builder
offers one horizontal shaping machines with provision for simultaneous shaping of more than one gear/spline
portion. Fig. shows a multi-cutter spline shaping of an automobile mainshaft. Three cutters on left side and
one on right side shapes four spline portions simultaneously.

Horizontal Multi-Cutter Shaping Operation

2.Column moving or table moving machine

For production application, preference is given for a column moving machine, where the machine column with cutter slide moves in
and away in relation to the stationary worktable. It provides the advantage of fixing up automatic loading and unloading
arrangement.

3. Table tilting or column tilting for taper shaping

The synchronising gear teeth in automobile transmission are designed with slight taper to avoid the automatic loss of engagement of
involute splines (trouble known as 'gear jumping'). Some special configurations of shaping machines (Fig. 4.13) are as follows:

1. Suitable tapered riserblock is used to tilt the machine column to specified angle of taper. The machine does not provide
for any change of taper angle unless the machine is reassembled with different taper riser block.
2. A tilting machine column allows to cut gears parallel to the axis as well as with a back taper within a range.
3. A tilting worktable is used on a standard machine. The table may be dedicated for an amount of taper or may have
provision for changing the tilt angle within a range.

Fig. Machine Configurations for Taper Shaping

,.
Advent of CNC Hobbing Machine: Automatic work cycle electro-hydraulic machines rely on electrically controlled and
hydraulically or mechanically performed functions with proximity switches, cams, etc. With programmable logic controller,
only cycle programming is done through console and electro-mechanical programming device. CNC control brought the
real revolution of built-in flexibility. Various CNC axes, Fig. 4.29 and their functions are
X- Variable radial feed, easy setting of depth of cut, precise positioning, close loop control of centre
distance of hob and gear and thus over pin size.
Y- Hob shifting rate and limits, memory function of the last position of hob before opening other
set- up, with position shift possible to use multiple hobs to cut several kinds of gears
Z- Variable axial feed.
A- Hob head swivel positioning.
B- Hob spindle variable speed and positioning for automatic hob change
C- Table rotation speed variable and gear synchronised for accurate generation.

A Full CNC Hobbing Machine

Advantages of CNC Hobbing Machines

CNC enhances the capabilities of the hobbing machine to a great extent. No calculations are required. Infinite possibilities for
the feed cycle with interpolation of various axes are available to achieve the design requirements and productivity
improvements. Some advantageous possibilities are:
Crowning or taper
Skip hobbing
Relief hobbing
Single indexing
Oblique hobbing
Double helical gear hobbing in single setup
Multiple gears (or splines) - different pitch, helix angle and number of teeth in single setup.
Hobbing of non circular gears.

CNC improves the quality, reduces the setup time and also the cycle time.
THANK YOU