31-Jul-21

Today’s topic:
Gear Manufacture

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Gear Terminology

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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Gear Terminology
Addendum - radial distance from pitch circle to the outside
diameter( addendum circle)
Dedendum - radial distance between the pitch circle and the
root diameter (dedendum circle)
Addendum circle - circle passing through the tips of teeth
Dedendum circle - circle passing through the roots of teeth
Pitch circle - a circle representing imaginary friction wheels
Circular thickness - the distance of the arc along the pitch
circle from one side of a gear tooth to the other

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Gear Terminology
Circular pitch - the length of the arc of the pitch circle from one point on a tooth
to the same point on the adjacent tooth
Chordal addendum - the distance from the top of the tooth to the chord
connecting the circular thickness arc
Chordal thickness - the thickness of a tooth on a straight line on the pitch circle
Whole depth - the total depth of a tooth space equal to the sum of the
addendum and dedendum
Working depth - the depth of engagement of two mating gears
Clearance - the amount by which the tooth space is cut deeper than the
working depth

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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Gear Terminology
Backlash - the amount by which the width of a tooth space
exceeds the thickness of the engaging tooth on the pitch circle
Diametral pitch - the ratio of number of teeth of a gear to the
pitch circle diameter
Pressure angle - the angle between the common normal and
common tangent to the pitch circle at the pitch point (point of
tooth contact)
Module - the ratio of pitch circle diameter(mm) to the
number of teeth

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Methods of Making Gears

The following methods for gear making are most common

Casting Extruding
-Sand casting Coining
-Permanent mould casting Rolling
-Die casting Machining
Powder metallurgy -Form cutting
Plastic moulding -Template method
Stamping -Generating method

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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 31-Jul-21

Methods of Making Gears

Casting - Gears may be cast in sand or permanent moulds. Large size cast iron gears
can be made at relatively low cost. They are rough, inaccurate and possess low
strength. This process is preferred where high precision is not required. The gears
produced in die casting possess high accuracy with good surface finish. They are used
for light services.
Powder metallurgy - Gears can be made cheaply with better control of properties than
casting. Gears with close dimensions can be produced and in most cases machining is
not required.
Plastic moulding - used for making gears from plastics. Gears produced are used for
very light loads. They are widely used because of the comparative ease of
manufacture, good wearing qualities and noiseless operation.
SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Methods of Making Gears

Stamping - used for making thin gears from sheet metal by using press. A wide variety
of materials such as copper-zinc alloys, aluminium alloys, plain carbon steel and
stainless steel can be used for making gears. The thickness of stamped gears is limited
to 1.5 mm and such gears are used in watches, toys and household gadgets.
Extruding - used for making spur gears. Brass and aluminium are most suitable
materials. A long length of bar is extruded through a die having the shape of the
desired teeth profile, then the required gears are cut from the extruded bar.
Coining - gears are manufactured from the blanks in a hydraulic press or forging
hammers. Gears manufactured by this process are accurate and does not require any
machining.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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Methods of Making Gears

Rolling - used for making gears from ductile materials. The process consists of forcing a
master gear into a hot blank which is in plastic state. The two are then rolled together
so that the teeth of master gear penetrates into blank to form a complete gear. The
teeth formed are then machined to obtain required accuracy and surface finish.
Machining - It is one of the most extensively used methods of producing accurate
gears. The various methods used for machining gears may be classified as follows:
Form cutting method
Template method and
Generating method

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Methods of Machining Gears

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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 31-Jul-21

Form Cutting Methods

Gear forming methods use a cutting tool having the
same form as the tooth space being cut. The cutter
may be a single point tool or a multi point cutting tool.
Gear cutting by a single point tool : A single point
cutting tool having the same form as the tooth space is
used to cut gears in a shaper or planer. The work is
mounted between the centres and the tool
reciprocates to produce the required tooth space. The
blank is then indexed for the next tooth space.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Form Cutting Methods

Gear cutting by form cutter : Gear forming is
carried out on milling machine using disc type
cutter or end mill cutter.
- Gear cutting by an end mill : The cutting edge
of the end mill is conformed to the shape of
the tooth space and is used for cutting large
module gears of above 20 mm where the use
of disc type cutters are unsuitable. End mill
cutters consume much less power in machining
as compared to disc type cutters.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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Form Cutting Methods

- Gear cutting by disc type milling cutter : It is carried
out on a horizontal milling machine. The cutter
profile is same as that of tooth space. The cutter
revolving at correct speed is moved radially into the
blank to obtain the correct tooth depth, and the
work fed across the cutter to complete the tooth
space. After milling a tooth space, the gear blank is
returned to its initial position and is then indexed to
the next tooth space. The blank is again moved
against the cutter, and the next tooth space is cut at
the preset depth. The procedure is repeated to cut
entire gear.
SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Form Cutting Methods

Broaching : It is usually employed for producing accurate internal gears by using a
broaching tool in a broaching machine. The cutting edges of broach are conformed to the
tooth space, and full form finished gears are produced in one pass of a circular broach. A
separate broach must be provided for each size of gear. It is mainly used for cutting
internal spur and helical gears. The initial cost of the tooling and equipment is high and is
only economical for mass production.

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

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Template Method
Gear cutting is carried out on a gear planer with a single point tool.
A reciprocating single point tool is guided by a master former or template whose profile
corresponds to the gear tooth being cut. The method is slow and is only used for cutting
large spur gears which are difficult to cut by form cutters. It is also used to cut bevel gears
accurately

SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE

Generating Methods
Generating methods are used for producing accurate gears in large quantities. Here, the
cutter meshes with the gear blank and is constrained to move in the right relationship to
the blank such that gear teeth are generated as the metal is machined. This principle is
based on the fact that any two gears of involute form having the same module and
pressure angle will mesh each other. In this process, one gear is made as a cutter and is
continuously in mesh with gear blank and the teeth are generated on the blank by the
relative coordinated rolling motion of the cutter and gear blank.
The generating principle is employed in the following processes for producing gears--
-gear planing using rack cutter
-gear shaping using pinion cutter and
-gear hobbing
SREERAJ A S, ST.MARY'S POLYTECHNIC COLLEGE