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Vimal
Vimal
TRAINING
REPORT
2017
INDUSTRIAL TRAINING PRESENTATION
ON
GEAR MANUFACTURING
BY : VIMAL MAHESHWARI
CONTENTS
ABOUT THECOMPANY
SLECTION OF MATERIAL
Selection of materials
processes include milling the tooth shape with formed cutters or generating the shape with a rack
Roughing processes:
Roughing process consists of forming, generation, shaping and hobbing processes. By this method gears are made
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
small volume production of low precision gears. The form milling by end mill cutter
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
gear blank . The accuracy is good, but any errors in one tooth of the shaper cutter will be directly transferred to the gear.
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
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
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
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Grinding:
In grinding, a contoured grinding wheel is run over machined surface of the gear teeth using computer control. With a
(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
in what amounts to an accelerated and controlled run-in to improve surface finish and the accuracy. Fig shows lapping
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.
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.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.
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.
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.
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.
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