Aim: To Perform Spur Gear Cutting Operation

11-A

GEAR NOMENCLATURE

MILLING OPERATION

Machine Shop/ Automobile Engineering/ Malnad College of Engineering

Aim: To Perform Spur Gear Cutting Operation

11-B

Machine Shop/ Automobile Engineering/ Malnad College of Engineering

Aim: To Perform Spur Gear Cutting Operation

25 10 30 10 40 10 35
3 O2

11-C

18

18

Spur Gear Calculations: Involute Gear cutter Pressure angle= 14( ) 0 Cutter selection:-Available in our Machine Shop cutters of size 6DP, 8DP, 10DP, 12DP, 14DP, 16DP, 18DP, 20DP. In each DP there are sets of 8 cutters according to Involute curve which varies from size to Rack. Cutter No-1 135-Rack

1 2

Cutter No-2 55-134 Cutter No-3 35-54 Cutter No-4 26-34 Cutter No-5 21-25 Cutter No-6 17-20 Cutter No-7 14-16 Cutter No-8 12-13 Indexing Plate Chart (Brown and Sharpe): Plate No-1= 15, 16, 17, 18, 19, 20 Plate No-2= 21, 23, 27, 29, 31, 33 Plate No-3= 37, 39, 41, 43, 47, 49

Machine Shop/ Automobile Engineering/ Malnad College of Engineering

18

Aim: To Perform Spur Gear Cutting Operation

For the Given DP=16 and the number of teeth N=12 Pitch Circle Diameter PD =

11-D

N 12 25.4 19.05mm DP 16

Module m =

PD 19.05 1.58 N 12 N 2 12 2 14 25.4 22.22 23mm DP 16 16

Outside Diameter =

Addendum =

1 1 25.4 1.587 mm DP 16 1.157 1.157 25.4 1.836mm DP 16

Dedendum =

Whole Depth = Addendum+Dedendum=3.423mm Simple Indexing =

40 40 1 = 3 revolutions N 12 3 1 15 5 holes .The crank is turned 3 revolution plus 3

A hole circle which can be divided by 3 of fraction is selected. If now 15 hole circle is selected from Index Plate No.1, then the 5 holes on 15 hole circle.

Machine Shop/ Automobile Engineering/ Malnad College of Engineering

Aim: To Perform Spur Gear Cutting Operation

11-E

Tools Required: Gear Milling Cutter, Indexing Plate with Sector arms, Dividing Head, Chuck -key, Spanner Theory: (1) Milling is a machining process which is performed with a rotary cutter with several cutting edges arranged on the periphery of the cutter. It is a multiple point cutting tool which is used in conjunction with a milling machine. This process is used to generate flat surfaces or curved profile and many other intricate shapes with great accuracy and having very good surface finish. Milling machines are one of the essential machines in any modern machine shop (2) Based on the directions of movement of the milling cutter and the feeding direction of the work piece, there are two possible types of milling (a) UP Milling [Conventional Milling] (b) Down Milling [Climbing Milling] The Up Milling is the Process of removing metal by a cutter which is rotated against the direction of travel of the work piece. The thickness of the chip in Upmilling is minimum at the beginning of the cut and reaches to the maximum when the cut terminates The Down milling is the process of removing metal by a cutter which is rotated in the same direction of travel of the work piece. The thickness of the chip is maximum when the tooth begins its cut and it reduces to the minimum when the cut terminates (3) The Indexing is the operation of dividing the periphery of a piece of work into any number of equal parts. In Cutting Spur Gear, equal spacing of teeth on the Gear blank is performed by Indexing In Simple Indexing, the work piece 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 piece to rotate one-fortieth of a turn. Similarly, 40 turns of the crank will rotate the spindle and work piece 1 turn. Thus, there is a ratio of 40:1 between the turns of the Index crank and the dividing Head spindle. Further Indexing is made possible by having the Index plates with equi-spaced holes around various circles. This would allow for indexing the periphery of the work piece to any convenient number of divisions. Gear Terminology: Pitch Circle is the Imaginary Circle which by pure rolling action, would give the same motion as the actual Gear Pitch Circle Diameter or Pitch Diameter (PD) is the diameter of the pitch circle. The size

of the Gear is usually specified by the pitch circle diameter. PD

N DP

Machine Shop/ Automobile Engineering/ Malnad College of Engineering

Aim: To Perform Spur Gear Cutting Operation

11-F

Pressure angle is the angle formed by a line through the point of contact of two mating teeth and tangent to the two base circles and a line at right angles to the center line of the gears Addendum is the radial distance between the pitch circle and the outside diameter or

the height of the tooth above the pitch circle. Addendum=

1 DP

The clearance is the radial distance between the top of one tooth and the bottom of the mating tooth space Dedendum is the radial distance from the pitch circle to the bottom of the tooth space.

The dedendum is equal to addendum plus the clearance. Dedendum=

1.157 DP

Circular Pitch (CP) is the distance from a point on one tooth to a corresponding point

on the next tooth measured on the pitch circle. CP=

PD N

Diametral Pitch (DP) [Inch Gears] is the ratio of the number of teeth for each inch of

pitch diameter of the Gear. DP=

N 2 OD

Outside diameter is the overall diameter of the Gear, which is the pitch circle plus two

addendum. OD=

N 2 DP

Whole depth is the full depth of the tooth or the distance equal to the addendum plus the dedendum Module (m) [Metric Gears] is the pitch diameter of a gear in millimeter divided by the

number of teeth. m=

PD N

Involute is the curved line produced by a point of a stretched string when it is unwrapped from a given cylinder

Procedure: 1. For the given DP or OD and the number of teeth, calculate all the necessary Gear data 2. Calculate the Indexing. In this case for DP=16 and N=12, it is 3 3. Mount 16 DP#8 cutter on the Arbor 4. Mount Index Plate No.1 on the Dividing Head

1 revolutions 3

Machine Shop/ Automobile Engineering/ Malnad College of Engineering

Aim: To Perform Spur Gear Cutting Operation

11-G

5. Loosen the Index Crank nut and set the Index Pin into a hole on the 15-hole circle(If 15-hole circle is selected) 6. Tighten the Index Crank Nut and check to see that the Pin enters the hole easily 7. Loosen the set screw on the sector arm 8. Place the narrow edge of the left arm against the Index pin 9. Count 5 holes on the 15-hole circle. Do not include the hole in which the Index crank pin is engaged 10. Move the right sector arm slightly beyond the fifth hole and tighten the sector arm setscrew 11. Align the cutter with the work piece and move the table so that cutter clears the end of the work 12. Set the depth of cut and take the first cut 13. Now, stop the cutter & return the table to the original starting position 14. Withdraw the Index pin and turn the crank clock wise three full revolution plus the 5 holes indicated by the right sector arm. Release the Index pin between the fourth and fifth holes, and gently tap it until it drops into the fifth hole. 15. Turn the sector arm farthest from the pin clockwise until it is against the Index pin 16. Lock the dividing Head, then continue machining and indexing for the remaining teeth

Machine Shop/ Automobile Engineering/ Malnad College of Engineering