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UNIT 3

GEAR

OBJECTIVES

General Objective : To understand the technology of gears manufacturing Specific Objectives : At the end of the unit you will be able to: Know the methods of gear manufacturing Know the methods of direct and simple indexing Apply direct and simple indexing when cutting gears on a milling machine. Apply various formula to calculate gear-tooth dimensions.

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INPUT

3.0. GEAR MANUFACTURING Gears can be manufactured by casting, forging, extrusion, drawing, thread rolling, powder metallurgy, and blanking sheet metal (for making thin gears such as those used in watches and small clocks). Nonmetallic gears can be made by injection molding and casting. Gears may be as small as those used in watches or a large as 9 m in diameter. The dimensional accuracy and surface finish required for gear teeth depend on its intended use. Poor gear-tooth quality contributes to inefficient energy transmission and noise and adversely affects the gears frictional and wear characteristics. Submarines gears, for examples, have to be of extremely high quality so as to reduce noise levels, helping the submarine avoid detection. There two basic gear manufacturing methods which involve the machining of a wrought or cast gear blank: form cutting and generating. 3.1. FORM CUTTING In form cutting, the cutting tool is similar to a form-milling cutter made in the shape of the space between the gear teeth (Fig. 3.1). The gear-

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tooth shape is produced by cutting the gear blank around its periphery. The cutter travels axially along the length of the gear tooth at the appropriate depth to produce the gear tooth profile. After each tooth is cut, the cutter is withdrawn, the gear blank is rotated (indexed), and the cutter proceeds to cut another tooth. The process continues until all teeth are cut. Each cutter is designed to cut a range of number of teeth. The precision of the form cut tooth profile depends on the accuracy of the cutter and on the machine and its stiffness. Although inefficient, form cutting can be done on milling machines, with the cutter mounted on an arbor and the gear blank mounted in a dividing head.
Form cutter

Gear blank

Figure 3.1. Producing gear teeth on a blank by form cutting

Because the cutter has a fixed geometry, form cutting can only be used to produce gear teeth that have constant width, that is, on spur or helical gears but not on bevel gears. a machine similar to a shaper. Broaching can also be used to produce gear teeth and is particularly applicable to internal teeth. The process is rapid and produces fine surface finish with high dimensional accuracy. However, because broaches are Internal gears and gear teeth on straight surfaces, such as in rack and pinion, are form cut with a shaped cutter, using

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expensive and a separate broach is required for each gear size, this method is suitable almost exclusively for high-quantity production. Gear teeth may be cut on special machines with a single-point cutting tool that is guided by a template in the shape of the gear tooth profile. As the template can be made much larger than the gear tooth, dimensional accuracy is improved. Form cutting is relatively a simple process and can be used for cutting gear teeth with various profiles, however, it is a slow operation, and some types of machines require skilled labor. Consequently, it is suitable only for low-quantity production. Machines with semiautomatic features can be used economically for form cutting on a limited production basis. 3.2. GEAR GENERATING The cutting tool used in gear generating may be one of the following: 3.2.1. A pinion-shaped cutter 3.2.2. A rack-shaped straight cutter 3.2.3. A hob 3.2.1. The pinion-shaped cutter can be considered as one of

gears in a conjugate pair and the other as the gear blank (Fig 3.2); it is used on machines called gear shapers (Fig 3.3). The cutter has an axis parallel to that of the gear blank and rotates slowly with the blank at the same pitch-circle velocity in an axial reciprocating motion. A train of gears provides the required relative motion between the cutter shaft and the gear-blank shaft.

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Gear cutter

Base circle Pitch circle

Gear blank Base circle

Figure 3.2. Gear generating in a gear shaper using a pinion-shaped cutter

Cutter spindle Spacer Pinion-shape cutter Gear teeth

Gear blank

Figure 3.3.. Gear generating with a pinion-shaped gear cutter

Cutting may take place at either the down stroke or the upstroke of the machine. Because the clearance required for cutter travel is small, such as flanges (Fig 3.3). The process can be used for low-quantity as well as high-quantity production. 3.2.2. On a rack shaper, the generating tool is a segment of a

rack (Fig.3.4) which reciprocates parallel to the axis of the gear blank. Because it is not practical to have more than 6 to 12 teeth on a rack cutter, the cutter must be disengaged at suitable intervals and returned to the starting point; the gear blank remain fixed.

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Figure 3.4. Gear generating with rack-shaped cutter

3.2.3.

A gear-cutting hob (Fig. 3.5) is basically a worm, or screw,

made into a gear-generating tool by machining a series of longitudinal slots or gashes into it to form the cutting teeth. When hobbing a spur gear, the angle between the hob and gear blank axes is 90o minus the lead angle at the hob threads. All motions in hobbing are rotary, the hob and gear blank rotate continuously, much as two gears meshing until all teeth are cut.

Top view

Gear blank

Hob

Gear blank

Figure 3.5. View of gear cutting with a hob

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Hobs are available with one, two, or three threads. If the hob has a single thread and the gear is to have 40 teeth, for example, the hob and gear spindle must be geared together so that the hob makes 40 revolutions while the gear blank makes one revolution. Similarly, if a double-threaded hob is used, the hob would make 20 revolutions to the gear blanks one revolution. In addition, the hob must be fed parallel to the gear axis for a distance greater than the face width of the gear tooth (Fig. 3.5) in order to produce straight teeth on spur gears. The same hobs and machines can be used to cut helical gears by tilting the axis of the hob spindle. Because it produces a variety of gears rapidly and with good dimensional accuracy, gear hobbing is used extensively in industry. Although the process is suitable for low-quantity production, it is most economical for medium to high-quantity production. Geargenerating machines can also produce spiral-bevel and hypoid gears. Like most other machine tools, modern gear-generating machines are computer controlled. using indexable milling cutters. 3.3. CUTTING BEVEL GEARS Straight bevel gears are generally roughed out in one cut with a form cutter on machines that index automatically. The gear is then finished to the proper shape on a gear generator. The generating method is analogous to the rack-generating method already described. The cutters reciprocate across the face of the bevel gear as does the tool on a shaper (Fig 3.6). Multi axes computer-controlled machines are capable of generating many types and sizes of gears

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Gear blank Cutter

Figure 3.6. Cutting a straight bevel gear blank with two cutter
The machines for spiral bevel gears operate on essentially the same principle. The spiral cutter is basically a face-milling cutter that has a number of straight-sided cutting blades protruding from its periphery ( Fig.3.7 ).

Cutter

Gear blank

Figure 3.7. Cutting a spiral bevel gear with a single cutter

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3.4 GEAR-FINISHING PROCESSES As produced by any of the process described, the surface finish and dimensional accuracy of gear teeth may not be sufficiently accurate for certain applications. Moreover, the gears may be noisy or their mechanical properties, such as fatigue life, may not be sufficiently high. Several finishing processes are available to improve the surface quality of gears. The choice of process is dictated by the method of gear manufacture and whether the gears have been hardened by heat treatment. Heat treating can cause distortion of parts. Consequently, for precise gear-tooth profile, heat-treated gears should be subjected to appropriate finishing operations. 3.4.1. Shaving The gear shaving process involves a cutter, made in the exact shape of the finished tooth profile, which removes small amounts of metal from the gear teeth. The cutter teeth are slotted or gashed at several points along its width, making the process similar to fine broaching. The motion of the cutter is reciprocating. Shaving and burnishing can only be performed on gears with a hardness of 40 HRC or lower. Although the tools are expensive and special machines are necessary, shaving is rapid and is the most commonly used process for gear finishing. It produces gear teeth with improved surface finish and improved accuracy of tooth profile. Shaved gears may subsequently be heat treated and then ground for improved hardness, wear resistance, and accurate tooth profile.

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3.4.2. Burnishing The surface finish of gear teeth can also be improved by burnishing. Introduced in the 1960s, burnishing is basically a surface plastic-deformation process using a special hardened gear-shaped burnishing die that subjects the tooth surfaces to a surface rolling action (gear rolling). Cold working of tooth surfaces improves the However, burnishing does not surface finish and induces surface compressive residual stresses on the gear teeth, thus their fatigue life. significantly improve gear-tooth accuracy. 3.4.3. Grinding, honing and lapping For the highest dimensional accuracy, tooth spacing and form, and surface finish, gear teeth may subsequently be ground, honed, and lapped. Specially-dressed grinding wheels are used for either forming or generating gear-tooth surfaces. There are several types of grinders of gears, with the single index form grinder being the most commonly available. In form grinding, the shape of the grinding wheel is identical to that of the tooth spacing (Fig. 3.8) The honing tool is plastic gear impregnated with fine abrasive particles. The process is faster than grinding and is used to improve surface finish. To further improve the surface finish, ground gear teeth are lapped using abrasive compounds with either a gear-shaped lapping tool (made of cast iron or bronze) or a pair of mating gears that are run together. Although production rates are lower and costs are higher, these finishing operations are particularly suitable for producing hardened gears of very high quality, long life, and quiet operation.

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Grinding wheel

Gear

Position: 15o or 0o

Position: 0o

Figure 3.8. Grinding by generating with two wheels

3.5. METRIC GEARS AND GEAR CUTTING Countries which have been using a metric system of measurement usually use the module system of gearing. The module (M) of a gear equals the pitch diameter (PD) divided by the number of teeth (N), or M = only, whereas the DP of a gear is the ratio of N to the PD, or DP =
N . The DP of PD

a gear is the ratio of the number of teeth per inch diameter, whereas M is an actual dimension. Most of the term used in DP gears remains the same for module gears; however, the method of calculating the dimensions has changed in some instances. Table 3.2. gives necessary rules and formulas for metric spur gears.

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3.6. METRIC MODUL GEAR CUTTERS The most common metric gear cutters are available in moduls ranging from 0.5 to 10 mm. However metric modul gear cutters are available in sizes up to 75 mm. Any metric modul size is available a set of eight cutters, number from #1 to #8. The range of each cutter is the reverse of that of a DP cutter. For instance, a #1 metric modul cutter will cut from 12 to 13 teeth; a #8 DP cutter will cut from 135 teeth to a rack. Table 3.1. shows the cutters available and the range of each cutter in the set.

Table 3.1 Metric module gear cutter

Module size (mm) 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.50 5.00 5.50 6.00 6.50 7.00 8.00 9.00 10.00 1 2 3 4 5 6 7 8 12 13 teeth 14 16 teeth 17 20 teeth 21 25 teeth 26 34 teeth 35 54 teeth 55 134 teeth 135 teeth to rack Milling Cutter Numbers Cutter No. For Cutting

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Table 3.2. Formula for calculating metric gear

To Obtain Addendum (A) Knowing Normal Module Module Pitch diameter and number of teeth Outside diameter and number of teeth Module and outside diameter Chordal thickness (CT) Module Circular pitch Clearance (CL) Dedendum (D) Module Module Pitch diameter and number of teeth Circular pitch Outside diameter and number of teeth Pitch diameter and module Number of teeth (N) Pitch diameter and circular pitch Number of teeth and module Pitch diameter and module Module and number of teeth Outside diameter and module Number of teeth and outside diameter Whole depth (WD) Centre-to-centre distance(CD) Module Pitch diameters Rule Addendum equals module Multiply module by p Multiply pitch diameter by p and divide by number of teeth Multiply outside diameter by p and divide by number of teeth minus 2 Divide 90 by number of teeth. Find the sine of this angle and multiply by the pitch diameter. Multiply module by p and divide by 2 Divide circle pitch by 2 Multiply module 0.166 mm Multiply module 1.166 mm Divide pitch diameter by the module Divide circular pitch by p Divide outside diameter by number of teeth Divide pitch diameter by the module Multiply pitch diameter by p and divide product by circular pitch Add 2 to the number of teeth and multiply sum of module Add 2 modules to pitch diameter Multiply module by number of teeth Subtract 2 modules from outside diameter Multiply number of teeth by outside diameter and divide product by number of teeth plus 2 Multiply module by 2.166 mm Divide the sum of the pitch diameters by 2 Formula A=M CP = M x 3.1416 CP = M x CP =

Circular pitch (CP)

3.1416 N

OD x 3.1416 N-2
90 N

CT = PD x sin

CT =

M x 3.1416 2 CP CT = 2
CL = M x 0.166 D = M x 1.166

M= M= M= N= N=

Module (M)

PD N CP 3.1416 OD N+2 PD M PD x 3.1416 CP

Outside diameter (OD)

OD = (N + 2) x M OD = PD + 2M PD = M x N PD = OD 2M PD =

Pitch diameter (PD)

N x OD N+2 PD1 + PD 2 2

WD = M x 2.166 CD =

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Example 1. 1. A spur gear has PD of 60mm and 20 teeth. Calculate: (a) (b) (c) (d) (e) (f) (g). Solutions: (a) Modul = PD/N = 60/20 = 3 mm (b) CP =Mp = 3 3.1416 = 9.425 mm (c) Addendum = Modul = 3 mm (d). Outside diameter = ( N + 2 ) M = 22 3 = 66 mm (e). Dedendum = M 1.666 = 3 1.666 = 4.998 mm Modul Circular Pitch Addendum Outside diameter Dedendum Whole depth Cutter number

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(f) Working depth

= Modul 2.166 = 3 2.166 = 6.498 mm

(g). Cutter number ( see Table 3.2 ) = 3

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ACTIVITY 3A

3.1.

Two identical gears in mesh have a CD of 120 mm. Each gear has 24 teeth. Calculate; Pitch diameter Modul Outside diameter Whole depth Circular pitch Chordal thickness

(a) (b) (c) (d) (e) (f) 3.2.

Name 3 methods of gear generating.

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PD N

FEEDBACK ON ACTIVITY 3A

3.1.(a)PD

= = = =
PD N 120 24

2xCD 2 2x120 2 240 2

( equal gears )

120 mm

(b)

= =

= 5 (c) OD = (N + 2 ) x M = 26 x 5 = 130 mm (d) WD = M x 2.166 = 5 x 2.166 = 10.83 mm

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(e)

CP

= MxP = 5 x 3.1416 = 15.708 mm

(f)

CT

Mx 2
5x3.1416 2

7.85 mm

3.2.

1. 1. 2.

Pinion- shaped cutter Rack-shaped straight cutter A hob

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3.7. THE INDEXING OR DIVIDING HEAD The indexing or dividing head is one of the most important attachments for the milling machine. It is used to divide the circumference of a work piece into equally spaced divisions when milling gears, splines, squares and hexagons. It may also be used to rotate the work piece at a predetermined ratio to the table feed rate to produce cams and helical grooves on gears, drills, reamers, and other parts. 3.8. INDEX HEAD PARTS The universal dividing head set consists of the headstock with index plates, headstock change and quadrant, universal chuck, footstock, and the centre rest ( Fig 3.9 ). A swiveling block mounted in the base enables the headstock to be tilted from 5o below horizontal position to 10o beyond the vertical position. The side of the base and the blocks are graduated to indicate the angle of the setting. Mounted in the swiveling block is a spindle, with 40-tooth worm wheel attached, which meshes with a worm ( Fig. 3.10 ). The worm , at right angles to the spindle, is connected to the index crank, the pin of which engages in the index plate. A direct indexing plate is attached to the front of the spindle. A 60o centre may be inserted into the front of the spindle, and a universal chuck may be threaded onto the end of the spindle. The footstock is used in conjunction with the headstock to support work held between centers or the end of work held in a chuck. The footstock centre may be adjusted longitudinally to accommodate various lengths of work and may be raised or lowered off centre. It may also be tilted out of parallel with the base when cuts are being made on tapered work.

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Long, slender work held between centers is prevented from bending by the adjustable centre rest.

Figure 3.9. A universal dividing head set

Figure 3.10 Section through a dividing head, showing the worm wheel and worm shaft

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3.9 METHODS OF INDEXING The main purpose of the indexing or dividing head is to divide the work piece circumference accurately into any number of divisions. This may be accomplished by the following indexing methods: direct, simple, angular, and differential. However, this modul will only cover direct and simple indexing. 3.9.1. Direct indexing Direct indexing is the simplest form of indexing. It is performed by disengaging the worm shaft from the worm wheel by means of an eccentric device in the dividing head. Some direct dividing heads do not have a worm and worm wheel but rotate on bearings. The index plates contain slots, which are numbered , and a spring-loaded tongue lock is used to engage in the proper slot. Direct indexing is used for quick indexing of the work piece when cutting flutes, hexagons, squares, and other shapes. The work is rotated the required amount and held in place by a pin which engages in to a hole or slot in the direct indexing plate mounted on the end of the dividing head spindle. The direct indexing plate usually contains three sets of hole circles or slots: 24, 30, and 36. The number of divisions it is possible to index is limited to numbers which are factors of either 24, 30, or 36. The common divisions that can be obtain by direct indexing are listed in Table 3.3

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Table 3.3. Direct Indexing Divisions

Plate Hole Number 24 30 36 Example: What direct indexing is necessary to mill eight flutes on a reamer blank? As the 24 hole circle is the only one divisible by eight (the required of divisions), it is the only circle which can be used in this case. 2, 3, 4, -, 6, 8, ----- 12 24 2, 3, -, 5, 6, -, -, -, 10, -, -, 15, .30 3, 4, -, 6, -, 9, -, 12, -, 18, 36

Indexing =

24 = 3 holes on a 24-hole circle. 8

Note: Never count the hole or slot in which the index pin is engaged. To mill a square by direct indexing 1. Disengage the worm and worm shaft by turning the worm disengaging shaft lever if the dividing head is so equipped. 2. Adjust the plunger behind the index plate into the 24-hole circle or slot (Fig. 3.11. ).

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Plunger pin lever

Figure 3.11. Adjusting the plunger pin to fit into the proper hole circle or slot
3. Mount the work piece in the dividing head chuck or between centers. 4. Adjust the cutter height and cut the first side. 5. Remove the plunger pin using the plunger pin lever ( Fig. 3.11.). 6. Turn the plate, attached to the dividing head spindle, one-half turn (12 holes or slots) and engage the plunger pin. 7. Take the second cut. 8. Measure the work across the flats and adjust the work height if required. 9. Cut the remaining sides by indexing every six holes until all surfaces are cut.

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Figure 3.12 The plunger pin and the direct indexing plate are used for indexing a limited number of divisions.

3.9.2. Simple Indexing In simple indexing, the work is positioned by means of the crank, index plate, and sector arms. The worm attached to the crank must be engaged with the worm wheel on the dividing head spindle. Since there are 40 teeth on the worm wheel, one complete turn of the index crank will cause the spindle and the work to rotate one-fortieth of a turn. Similarly, 40 turns of the crank will revolve the spindle and work one turn. Thus there is a ratio of 40:1 between the turns of the index crank and the dividing head spindle. To calculate the indexing or the number of turns of the crank for most divisions, it is necessary only to divide 40 by the number of division (N) to be cut, or Indexing =
40 N

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Example: The indexing required to cut eight flutes would be:

40 = 5 full turns of the index crank 8

If, however, it was necessary to cut seven flutes, the indexing would be
40 5 =5 7 7

turns

Five complete turns are easily made; however, the five seventh of a turn involves the use of the index plate and sector arms. Index plate and sector arms The index plate is a circular plate provided with a series of equally spaced holes into which the index crank pin engages. The sector arms fit on the front of this plate and may be set to any portions of a complete turn. To get five-sevenths of a turn, choose any hole circle ( Table 3.4.) which is divisible by the denominator 7, such as 21, then take five-sevenths of 21 = 15 holes on a 21-hole circle. Therefore, the indexing for seven flutes would be
40 5 =5 7 7

turns or 5 complete turns plus 15 holes on the 21-hole circle.

When extreme accuracy is required for indexing, choose the circle with the most holes.

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Table 3.4. Index plate hole circle

Brown and Sharpe Plate 1 Plate 2 Plate 3 One side Other side 15-16-17-18-19-2021-23-27-29-31-33 37-39-41-43-47-49 Cincinnati Standard Plate 24-25-28-30-34-37-38-39-41-42-43 46-47-49-51-53-54-57-58-59-62-66

The procedures for cutting seven flutes would be as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Mount the proper index plate on the dividing head. Loosen the index crank nut and set the index pin into a hole on the 21-hole circle. Tighten the index crank nut and check to see that the pin enters the hole easily. Loosen the set screw on the sector arms. Place the narrow edge of the left arms against the index pin. Count 15 holes the 21-hole circle. Do not include the hole in which the index crank pin is engaged. Move the right sector arms slightly beyond the 15th hole and tighten the sector arm setscrew. Align the cutter with the work piece. Start the machine and set the cutter to the top of the work by using a paper feeler ( Fig. 3.15 ). Move the table so that the cutter clears the ends of the work. Tighten the friction lock on the dividing head before making each cut and loosen the lock when indexing for spaces. Set the depth of cut and take the first cut.

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13. 14.

After the first flute has been cut, return the table to the original starting position. Withdraw the index pin and turn the crank clockwise five full turns plus the 15 holes indicated by the right sector arm. Release the index pin between the 14th and 15th holes, and gently tap it until it drops into the 15th hole.

15.

Turn the sector arm farthest from the pin clockwise until it is against the index pin.

NOTE:

It is important that the arm farthest from the pin be held and

turned. If the arm next to the pin were held and turned, the spacing between both sector arms could be increased when the other arm hit the pin. This could result in an indexing error which would not be noticeable until the work was completed. 16. Lock the dividing head; then continue machining and indexing for the remaining flutes. Whenever the crank pin is moved past the required hole, remove the backlash between the worm and worm wheel by turning the crank counterclockwise approximately one-half turn and then carefully clockwise until the pin engages the proper hole.

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3.10. TO CUT A SPUR GEAR The procedure for machining a spur gear is outlined in the following: Procedure: 3.1.1. Calculate the necessary gear data, refer to Table 3.1 Two identical gears in mesh have a CD of 120 mm. Each gear has 24 teeth. Calculate; i. Pitch diameter ii. Modul iii. Outside diameter iv. Whole depth v. Circular pitch vi. Chordal thickness
2xCD 2 2x120 2 240 2

3.1.1.i.

PD

= = = =
PD N 120 24

( equal gears )

120 mm

ii

= =

= 5

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iii. OD

= (N + 2 ) x M = 26 x 5 = 130 mm

iv WD

= M x 2.166 = 5 x 2.166 = 10.83 mm

v.

CP

= MxP = 5 x 3.1416 = 15.708 mm

vi.

CT

= =

Mx 2
5x3.1416 2

=7.85 mm 2. 3. Turn the gear blank to proper outside diameter Press the gear blank firmly onto the mandrel.

NOTE: If the blank was turned on a mandrel, be sure that it is tight because the heat caused by turning might have expanded the blank slightly. 4. Mount the index head and footstock, and check the alignment of the index centers ( Fig. 3.13. ).

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Figure 3.13. Checking the alignment of index centers with a dial indicator

5.

Set the dividing head so that the index pin fits into a hole on the 39- hole circle and the sector arms are set for 30 holes.

NOTE: Do not count the hole in which the pin is engaged. 6. Mount the mandrel (and work piece), with the large end toward the indexing head, between the index centers. NOTE: a. The footstock centre should be adjusted up tightly into the mandrel and lock in position. b. The dog should be tightened properly on the mandrel and the tail of the dog should not blind in the slot. c. The tail of the dog should then be locked in the driving fork of the dividing head by means of the sets screws.

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d. This will ensure that there will be no play between the dividing head and the mandrel. e. The dog should be far enough from the gear blank to ensure that the cutter will not hit the dog when the gear is being cut. 7. 8. Move the table close to the column to keep the setup as rigid as possible. Mount a cutter on the milling machine arbor over the approximate centre of the gear. Be sure to have the cutter rotating in the direction of the indexing head. 9. Centre the gear blank with the cutter by either of the following methods: a. Place a square against the outside diameter of the gear (Fig 2.23). With a pair of inside calipers or a rule, check the distance between the square and the side of the cutter. Adjust the table until the distances from both sides of the gear blank to the sides of the cutter are the same.

Figure 3.10.. Centering a gear cutter and the work piece

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b. A more accurate method of centralizing the cutter is to use gauge blocks instead of the inside calipers or rule. 10. LOCK THE CROSSLIDE. 11. Start the milling cutter and run the work under the cutter. 12. Raise the table until the cutter just touches the work. This can be done by using a chalk mark on the gear blank or a piece of paper between the gear blank and the cutter to indicate when the cutter just touching the work ( Fig. 3.15 ).

Figure 3.15. Setting a gear cutter to the diameter of the work piece
13. Set the graduated feed collar on the vertical feed to zero (0). Move the work clear of the cutter by means of the longitudinal feed handle and raise the table to about two-thirds the depth of the tooth (4.572 mm); then lock the knee clamp. NOTE: A special stocking cutter is sometimes used to rough out the teeth. 14. Slightly notch all gear teeth on the end of the work to check for correct indexing ( Fig. 3.16 ).

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Figure 3.16. Notching all gear teeth eliminates errors

15. Rough out the first tooth and set the automatic feed trip dog after the cutter is clear of the work. 16. Return the table to starting position. NOTE: Clear the end of the work with a cutter. 17. Cut the remaining teeth and return the table to the starting position. 18. Loosen the knee clamp, raise the table to the full depth of 0.270 in., and lock the knee clamp. NOTE: It is advisable to remove the crank from the knee elevating shaft

so that it will not be moved accidentally and change the setting. 19. Finish-cut all teeth. NOTE: After each tooth has been cut, the cutter should be stopped before the table is returned to prevent marring the finish on the gear teeth.

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ACTIVITY 3B

3.3. 3.4. 3.5. 3.6.

What direct indexing is necessary to mill 8 flutes on a reamer blank ? Explain how the ratio 40:1 is determined on a standard dividing head. What procedure should you follow in order to set the sector arms for 12 holes on an 18-hole circle ? With the aid of a labelled diagram, list down the procedures to align the index centers. How would you center the gear blank with the cutter ?

3.7.

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FEEDBACK ON ACTIVITY 3B

3.3.

Indexing

NOTE:

24 8 = 3 holes in a 24-holes circle Never count the hole/slot in which the index pin is engaged.

3.4. The index head spindle carries a 40-tooth worm wheel, which meshes with a worm. The worm ( at right angle to the spindle ) is connected to the index crank, the pin of is engaged in the index plate. Since there are 40 teeth on the worm wheel, one complete turn of the index crank will cause the spindle and the work to rotate 1/40th of a turn. Similarly 40 turns will revolve the spindle and the work one turn. Thus there is a ratio of 40:1 between the turns of the index crank and the dividing head spindle. 3.5. Index plate and sector arms The index plate is a circular plate provided with a series of equally spaced holes into which the index crank pin engages. The sector arms fit on the front of this plate and may be set to any portions of a complete turn. To get 12 holes in an 18-hole circle choose plate no. 1 of Brown and Sharpe index plate. Follow these procedures: 1. 2. 3. 4. Mount the index plate no. 1 on the dividing head. Loosen the index crank nut and set the index pin into a hole on the 18-hole circle. Tighten the index crank nut and check to see that the pin enters the hole easily. Loosen the set screw on the sector arms.

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5. 6. 7.

Place the narrow edge of the left arms against the index pin. Count 12 holes the 18-hole circle. Do not include the hole in which the index crank pin is engaged. Move the right sector arms slightly beyond the 12th hole and tighten the sector arm setscrew.

3.6. 1. Mount the index head and footstock, and check the alignment of the index centers.

Checking the alignment of index centers with a dial indicator

2.

Set the dividing head so that the index pin fits into a hole on the 39- hole circle and the sector arms are set for 30 holes.

NOTE: Do not count the hole in which the pin is engaged. 3. Mount the mandrel (and work piece), with the large end toward the indexing head, between the index centers.

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NOTE: a. The footstock centre should be adjusted up tightly into the mandrel and lock in position. b. The dog should be tightened properly on the mandrel and the tail of the dog should not blind in the slot. c. The tail of the dog should then be locked in the driving fork of the dividing head by means of the sets screws. d. This will ensure that there will be no play between the dividing head and the mandrel. e. The dog should be far enough from the gear blank to ensure that the cutter will not hit the dog when the gear is being cut. 3.7. Centre the gear blank with the cutter by either of the following methods: a. Place a square against the outside diameter of the gear. With a pair of inside calipers or a rule, check the distance between the square and the side of the cutter. Adjust the table until the distances from both sides of the gear blank to the sides of the cutter are the same.

.. Centering a gear cutter and the work piece

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SELF-ASSESSMENT 3

1. Calculate the tooth caliper settings for measuring the following gears. (a) 37T, 6 mm module; (b) 40T 20 mm circular pitch.

2. The figure below shows two (2) gears in mesh. Gear A has 66 teeth and modul 2.5. The gear ratio is 3:2. Calculate the following: (a). (b). (c). (d). Outside diameter of gear and pinion Number of teeth of pinion Centre distance of gear and pinion Whole depth of gear 66T

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FEEDBACK OF SELF-ASSESSMENT 3

1. (a) 9.4128 mm, 6.111 mm (b) 9.995 mm, 6.4923 mm. 2. (a) 170 mm, 115 mm. (b) 44, 165 mm, 110 mm (c) 137.50 mm (d) 5.415 mm