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Gear Shaping

The document discusses the gear shaping process for manufacturing gears. Gear shaping involves cutting gear teeth into a workpiece using a shaping cutter guided by a template on a gear shaping machine. The process produces gears with high accuracy and precision. It can create many gear types, including spur gears and helical gears. The document outlines the steps of the gear shaping process, lists the advantages of high accuracy and versatility, and discusses applications in automotive, aerospace, power generation, medical, and other industrial fields.

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85 views

Gear Shaping

The document discusses the gear shaping process for manufacturing gears. Gear shaping involves cutting gear teeth into a workpiece using a shaping cutter guided by a template on a gear shaping machine. The process produces gears with high accuracy and precision. It can create many gear types, including spur gears and helical gears. The document outlines the steps of the gear shaping process, lists the advantages of high accuracy and versatility, and discusses applications in automotive, aerospace, power generation, medical, and other industrial fields.

Uploaded by

abdo.nabil3333333
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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MDP384s: Metal Cutting Machines

and Technology
Design and Production Engineering Department
Senior 1 Level
Fall 2022

Report ( gear shaping )


Topic: gear shaping
Name: Fady kamal Awad
ID:1901147
Section: 2

Submitted to:
Dr. Mohamed Adel Rizk
Eng. Islam Elsaid
Introduction:-

Gear shaping is a manufacturing process used to produce gears with


highly accurate and precise teeth profiles. It involves cutting the teeth on
the gear using a gear shaping machine, which shapes the gear by a
shaping cutter. This is a highly efficient process that is extensively used
in the production of gears for automobiles, aerospace, and industrial
applications.

The gear shaping process is highly versatile and can produce a wide
variety of gear types, including spur gears, helical gears, crown gears, and
more. The accuracy and precision of the gears produced through the gear
shaping process are essential in ensuring the smooth and efficient
operation of mechanical systems.

The gear shaping process involves a variety of factors, including cutter


specifications, cutting speeds, feed rates, and other parameters. The
process requires a high degree of skill and experience to achieve the
desired level of accuracy and precision.

Overall, gear shaping is an essential process in the manufacturing of


gears, and its importance in mechanical systems cannot be overstated.
With advancements in technology, gear shaping machines have become
increasingly sophisticated, allowing for greater accuracy, efficiency, and
flexibility in gear production.

Types of gear shaping


1- Rack cutter
2- Pinion cutter
Overview of Gear Manufacture by Shaping Method:
The gear manufacturing process by shaping method involves the
following steps:
1- Selection of Workpiece: The first step is to select a workpiece,
which is typically a cylindrical blank made of metal or plastic. The
size and shape of the workpiece will depend on the type of gear
being produced.
2- Mounting the Workpiece: The workpiece is then mounted on a
rotating spindle in the shaping machine. The spindle rotates the
workpiece at a specific speed, which is determined by the size and
material of the workpiece.
3- Setting up the Template: The template is then set up on the shaper
machine. The template is a specially designed pattern that guides
the cutting tool in creating the gear teeth. The template is typically
made of metal or plastic and is carefully machined to the required
shape and size.
4- Setting up the Cutting Tool: The cutting tool is then set up on the
shaping machine. The cutting tool is typically a small, sharp blade
made of highspeed steel or carbide. The cutting tool is mounted on
a reciprocating arm that moves back and forth across the
workpiece.
5- Cutting the Gear Teeth: Once the template and cutting tool are in
place, the cutting process can begin. As the spindle rotates the
workpiece, the cutting tool moves back and forth across the
workpiece, cutting the gear teeth into the surface of the workpiece.
The cutting tool is guided by the template, which ensures that the
gear teeth are cut to the exact shape and size required.
6- Finishing: Once the gear teeth have been cut, the workpiece is
removed from the shaping machine and inspected for any defects.
The gear teeth may be further finished or machined using other
methods, such as grinding or honing, to achieve the required
surface finish and accuracy.
7- Quality Control: Finally, the finished gear is inspected to ensure
that it meets the required specifications for size, shape, and
accuracy. Any defects or imperfections are identified and
corrected, if possible, before the gear is put into use.
Overall, the gear manufacturing process by shaping method is a
precise and controlled process that requires careful setup and attention
to detail. While it is slower than other gear manufacturing methods, it
is still widely used for its accuracy and versatility in producing a range
of gear types and sizes.

Advantages:

1. High accuracy: Gear shaping is a highly accurate process, which


can create gears with extremely precise teeth.
2. High productivity: Gear shaping machines are capable of producing
gears quickly and efficiently, particularly when compared to other
gear manufacturing techniques, such as broaching.
3. Versatility of gear design: Since gear shaping machines use a
specially designed cutter, it is possible to create virtually any type of
gear that is required.
4. Improved surface finish: Gear shaping helps to improve the surface
finish of the gears by removing any high spots and burrs, leaving a
smooth surface.

Disadvantages:

1. Expensive equipment: Gear shaping machines are expensive to


purchase and maintain and require a high level of technical knowledge
and expertise to operate.
2. Long changeover times: Changing from one gear to another can be
time-consuming and requires a higher degree of skill and experience.
3. Limited to certain gear types: Gear shaping is mainly suitable for
producing helical and spur gears and is not as suitable for bevel or
worm gears.
4. High tooling costs: Custom tooling must be developed for each gear
design, which can add to the overall cost of manufacturing.
Applications :-

1. Automotive industry: Gear shaping is extensively used in the


automotive industry to produce a wide range of gears, including
differentials, pinions, and transmission gears.
2. Aerospace industry: Gear shaping is widely used in the aerospace
industry for producing gears that drive a wide range of components
from hydraulic pumps to actuators.
3. Power generation: Gear shaping is used in power generation
applications to produce gears required for wind turbines, water
turbines, and steam turbines.
4. Medical equipment: Gear shaping is widely used in the medical
industry to produce precision gears for medical equipment, including
surgical robots, medical imaging systems, and prosthetic limbs.
5. Industrial applications: Gear shaping is used in a wide range of
industrial applications such as machinery, textiles, printing presses,
and many more, to produce the gears required for their efficient
operation

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