PROJECT ON SPUR GEARS

INTRODUCTION TO SPUR GEARS

SPUR GEARS OR STRAIGHT CUT GEARS ARE THE SIMPLEST TYPE OF GEARS.THEY CONSIST OF A CYLINDER OR DISK WITH THE TEETH PROJECTING RADIALLY ,AND ALTHOUGH THEY ARE NOT STRAIGHT SIDED IN FORM,THE EDGE OF EACH TOOTH IS STRAIGHT AND ALIGNED PARALLEL TO THE AXIS OF ROTATION.

MANUFACTURING OF GEARS

EN 353 MATERIAL IS USED. OPERATION THAT IS FOLLOWED IN FOR MANUFACTURING SPEED GEARS IS AS FOLLOWS BROACHING AND SPLINES CHAMPHER(0.3*45) TURNING ,FACING BOTH SIDES ,CHAMFFERING TURNING ,FACING BOTH SIDES ,CHAMFFERING INSPECTION TO CHECK PARALLELISM OF GEARS HOBBING (50 GEAR TEETH) CHAMFERRING GEAR TEETH ON BOTH SIDES BROACH OIL GROOVES DEBURRING OIL GROOVES SHAVING 50 GEAR TEETH

OPERATION 1 BROACHING AND SPLINES

BROACHING IS A MACHINING PROCESS THAT USES A TOOTHED TOOL,CALLED A BROACH TO REMOVE MATERIAL.

OPERATION 2 CHAMFERRING
AFTER COMPLETION OF BROACHING PROCESS GEARS COMES FOR SECOND OPERATION IE CHAMFERRING THE HOLES .IN THIS PROCESS IN WHICH SHARP EDGES OF THE HOLE IS REMOVED .IN THIS OPERATION NO MACHINE IS USED,MAN WITH A KNIFE EDGED BASTERD FILE AS TOOL IS CHISELED ON THE HOLE UNTIL IT COMES TO REQUIRED DIMENSIONS.

OPERATION 3 ,4 TURNING ,FACING AND CHAMFFERING

ALL THE THREE PROCESS ARE CARRIED OUT BY SUND STRAND AUTOMATIC LATHE MACHINE .THIS MACHINE IS A COPYING MACHINE WHICH WORKS ACCORDING TO THE COMPONENT DESIGN.

OPERATION 5 INSPECTION OF PARALLELISM OF GEARS

THIS IS JUST A INSPECTION PROCESS FOR CHECKING THE GEARS DIMENSIONS AND ACCURACY IN THEM.THIS IS A VIRTUAL INSPECTION TECHNIQUE AND SNAP GAUGE IS USED TO CHECK IT.

OPERATION 6 HOBBING (50 GEAR TEETH)

HOBBING IS A MACHINING PROCESS FOR MAKING GEARS,SPLINES.HOBBING MACHINE IS ASPECIAL TYPE OF MILLING MACHINE.THE TEETH OR SPLINES ARE PROGRESSIVELY CUT INTO THE WORKPIECE BY A SERIES OF CUTS MADE BY A CUTTING TOOL CALLED A HOB.

OPERATIONS 7 CHAFFERING GEARS TEETH

CHAFERING THE GEAR TEETH IS OUR NEXT OPERATION .THIS IS AN IMPORTANT OPERATION AS TEETH AFTER HOBBING HAS BEEB LEFT OUT WITH SOME EXTRA MATERIAL OR SHARP EDGES WHICH ARE TO BE REDUCED BY CHAMFERRING TECHNIQUE ONLY.

OPERATION 8 BROACH OIL GROOVES

OIL GROOVES ARE THE PATH WAY OF OIL TO THE GROOVES SO THEY RE IMPORTANT TO MAKE TO PROVIDE PATHWAY TO OIL SO THAT IT CAN LUBRICATE THE SURFACE MESHING TOGETHER AND TO REDUCE FRICTION AND COOL THE SURFACE AND MINIMIZE THE WEAR AND TEAR.

OPERATION 9 DEBURRING OIL GROOVES

A BURR IS A RAISED EDGE OR SMALL PIECES OF MATERIAL REMAINING ATTACHED TO A WORKPIECE AFTER A MODIFICATION PROCESS.IT US USUALLY AN UNWANTED PIECE MATERIALAND WHEN REMOVED WITH A DEBURRING TOOL IN A PROCESS CALLED DEBURRING.

OPERATION 10 SHAVING 50 GEAR TEETH

GEAR SHAVING IS BASICALLY A FINISHING OPERATION .THE SHAVING PROCESS CONSIST OF THE REMOVAL OF TINY PARTICLES OF METAL FROM A GEAR TEETH WORKING SURFACE .GEAR SHAVING PRODUCES FINE HAIR LIKE CHIPS.THE CUTTER COMES IN THE FORM OF HELICAL GEAR.