Training Program: 12-12-2013

GEAR MANUFACTURING

P D Patil
 Training Program: 12-12-2013

• We must be clear about what we need,

• We are not gear designers,
• We manufacture gears as per customer
drawings,
• We must know to read the drawing and
means to comply the specifications,
• We must know the process and equipment.
 Gear Descriptions and Functions
• Gears transmit power and motion.
• Gears perform certain key functions :
• Reversing rotational direction
• Altering angular orientation of rotary motion
• Converting rotary to linear motion and vice-
versa
• Altering speed (Reduction gearbox)
Altering power transmission ratios
 Shape of Gear Tooth
• Tooth profile contour widely used is the
“INVOLUTE” curve.
• This facilitates interchangeability of gears.
• Operation of meshing gears is smooth.
• Manufacturing is easy.
• Cutting tools with same module and pressure
angle can be used for wide range of teeth.
• Tooth modifications are feasible.
Involute Curve
Involute
Gear Meshing
Gear Tooth
Application of Gears
Engine timing gears
Application of GEAR
Types of Gears
Internal Gear
How Gears are manufactured
Two ways of Gear Cutting
 HOBBING

• More popular process

• Productivity is high
• Higher cutting speeds and feeds can be
employed
• Tooth modifications such as Crowning, Taper,
Profile relief are possible
• LIMITATION: Gears having collar can not be
processed.
Hobbing: schematic
Conventional hobbing machine
Measurement: Gear Tooth
Gear hobbing

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Tooth generation: Hobbing
 Things to note (Hobbing)
• Work holding fixture to be rigid
• Hob condition, sharpness, proper mounting
ensured
• Avoid use of excess cutting speed & feed
• Be careful while choosing Multi start hob
• Main causes for errors at hobbing stage is
improper mounting of Hob and weak work
holding

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Hobbing: Surface Roughness: Scallop
Where-
dx = Scallop in
microns
do = Outside dia
of Hob
fa = Feed value,
mm/revolution.
Error: Hob Sharpening
Gear hobbing – kinematic schema

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After Hobbing
Sliding gears
Tooth Rounding/ Roofing
 Gear Shaping Process
• During 1980s this was considered superior to
gear hobbing for better surface finish
• This is the unique process to cut gears having
a collar or large diameter adjoining,
• AND
• Internal gears
• For cutting helical gears, you have to change
helical guide for cutter spindle every time
• Low Productivity
Example: Gear Shaping
Shaper
Gear shaping – the principle

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Gear shaping – a circular cutter

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Gear shaping – a circular cutter

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 Things to note (Gear Shaping)
• Fixture design must fit in M/c working height
• Backlash at worktable and cutter spindle
drives must be controlled
• Support for work and cutter must extend to
max possible dia
• Back off angle and amount to be adequate
• Backlash in index gear train affects quality
• Approach and over run to be carefully chosen
• Error in cutter sharpening gives wrong profile
Other methods in use for gear making
• Apart from Hobbing and Shaping, Broaching
and Rolling processes are widely used
• These are more productive
• Broaching is largely used to cut internal
splines, keyways, sector gears
• Rolling is used for serrations and splines of
minor modules (below 1.5 module)
• Rolled gears can not meet profile accuracies
• Rolling Dies can be Circular OR Rack type
 Broaching
• Very productive method
• Broach has the shape of gear
• Ideal for internal gears
– Tooth gaps one after another
– All gaps simultaneously
Desc.:
1 – elongated body, 2 – teeth, 3 –
gullets, 4 – teeth gaps, 5 – axis, 6 –
follower end, 7 – pull end, 10 – outside
shape of broach
Gear Rolling
Gear Rolling Types
 What after gear cutting
• When customer has specific demands on
component tooth profile and lead, Shaving
process is applied.
• Examples: surface finish, K-chart, crowning
• Shaving operation is done before H T
• Shaving is a two fold sword, it makes good job
better, but BAD job worst
• Plunge and conventional shaving methods
generally used. Underpass and diagonal rarely
Gear Shaving methods
 Spur and helical gears finishing
METHODS:
• shaving – for gears without heat treatment
• grinding – mostly for gears after heat treatment
- form grinding
- involute - generating grinding
• lapping
• teeth rounding – creating a shape of tooth (in the
direction parallely to the axis of rotation) to make
changing gears easier
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Shaving Machine
 GEAR WHEELS SHAVING
The gear and the cutter are run in mesh with their axes
crossed at a small angle. During the rotation the gear is
reciprocated longitudinally across the cutter.
This „shaving“ process causes very fine chips are cut from the
tooth surface (process requires less than 1 minute)

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Gear Shaving
Gear finishing of Hardened Gears:
After heat treatment, some
distortions take place.
If requirements are stringent, then
profile grinding, honing and
lapping are the alternatives
available.
Involute-generating grinder

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Form grinding of Gear
Generation grinding
 Gear lapping
• On finished, shaved and hardened gears.
• The gear runs in contact with one or more cast iron
lapping gears
• Flow of oil with abrasive is used
• Improves surface quality at low costs then grinding
• Ra = 0,1 – 0,2
 Gear Quality
• Every drawing mentions quality specifications
• DIN, AGMA, ANSI, JIS are commonly used
• Parameters mentioned can be ascertained by
employing gear checking machine
• Emphasis is on
• 1) Lead Errors
• 2) Profile Errors
• 3) Pitch Errors and
• 4) Radial run out
Measurement
What to Check
Profile Check
Lead Check
DFC