Scribd
Upload
209 views

Production Technology (IV Sem)

The document discusses various gear manufacturing and finishing processes. It describes the generating process where teeth are cut on a gear blank by a cutting tool. Key gear manufacturing methods covered are hobbing, shaping, and rack planing. Hobbing uses a rotating hob cutter to cut spur and helical gears. Shaping uses a reciprocating pinion cutter. Finishing processes like grinding, lapping, and honing are used to improve gear accuracy and surface finish after manufacturing.

Uploaded by

Shubham Agrawal
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
209 views

Production Technology (IV Sem)

The document discusses various gear manufacturing and finishing processes. It describes the generating process where teeth are cut on a gear blank by a cutting tool. Key gear manufacturing methods covered are hobbing, shaping, and rack planing. Hobbing uses a rotating hob cutter to cut spur and helical gears. Shaping uses a reciprocating pinion cutter. Finishing processes like grinding, lapping, and honing are used to improve gear accuracy and surface finish after manufacturing.

Uploaded by

Shubham Agrawal
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 24

PRODUCTION

TECHNOLOGY
(IVTH SEM)
Kurukshetra University
GEAR MANUFACTURING
Generating process
The cutting tool and the gear blank are
rigidly attached to their shafts and the two
gears mesh with each other.
The cutter develops teeth on the blank by
coordinated motion of both.
Both the gears rotate with same pitch-line
velocities.
Generation operation
The cutting gear is reciprocated and
radially fed into the blank until a required
depth.
Then the both gear are rotated slightly
after each cutting stroke.
Types of generating process
In mass production of gears following
methods are used:-
A) Gear Hobbing
B) Gear Shaping
C) Rack Planing
The method is highly productive and
produces gear with moderate accuracy.
Gear Hobbing
Used for spur and helical gears.
Cutter used-HOB
Hob is a rotating cutting tool(cylindrical body)
and has teeth arranged in helical thread
Single threads are cut on its surface and have
involute shape.
Gashes and Flutes are cut across the spiral thread
to create cutting edges at regular intervals.
It is similar to a worm and cuts like a milling
cutter.
Hobbing Operation
Hobbing has three operations:-
Hob rotation
Hob feed
Gear Blank Rotation.
The hob and gear blank are fastened to
shafts at rite angles. The HOB must be
tilted through a angle (α) in order to cut
straight spur gears with true involute
shape.
Hob and blank rotate about their axis.
Gear blank is move towards rotating hob to a
proper depth.
Feed the gear hob into the gear blank enabling the
teeth to be gradually cut on the blank.
Process goes on till the other end of blank is
reached.

The gear can be cut either by:


Conventional hobbing- direction of hob rotation
and work feed are opposite
Climb hobbing-direction of hob and work feed are
same
Limitation-cannot be used to cut internal gear
Gear Shaping
Used for cutting sockets, herringbone
gears, splines.
Make use of hardened pinion as a cutter
ground with top rake and clearance.
The cutter reciprocated vertically and also
both cutter and blank rotate at same pitch-
line velocity
The radial movement of the cutter is
when it has to be fed into the depth of the
cut.
Gear shaping operation
Cutter is fed into full depth with cutter
reciprocating and blank stationary
Both cutter and blank slowly rotate about
their axis until all teeth are generated on the
gear blank
In nutshell, for cutting action the cutter is
reciprocated along its own axis at high speed
along with a feed advance motion(both gears
rotate)
The reciprocating cutter cuts on the upstroke
or the down stroke. In downward movement,
some stock is removed
Advantage
Only one cutter is needed to cut all gear
of same pitch
Gear shaper process is much faster than
rotatory cutting
Rack planing process
The cutter is the form of rack.
Cutter is fed into full depth with cutter
reciprocating and blank stationary.
When the cutter and blank have rolled a
distance equal to one pitch the blank
ceases its rotation, the cutter is withdrawn
and returned to original starting position.
If helical gear to be cut then the cutter is
bent at angle of helix
Gear Finishing
When gears are produced economically
the processed used do not produce
accurate tooth profiles.
During heat treatment to make gears hard,
there may arise slight distortion and
surface roughness
Finishing operation required for quiet
operation and high class gears.
Objective of finishing
Improve accuracy
To have uniformity in elements like pitch,
profile, eccentricity and helix angle
For quiet operation at high speeds.
To improve life of gear and remove heat
treatment distortions.
Finishing methods
Gear shaving
Gear grinding
Gear burnishing
Gear lapping
Gear honing
Gear shaving
Removes small amount of metal from
flanks of gear teeth
Improves helix angle, eccentricity, tooth
spacing
Can remove tooth end load
concentrations, reduce gear noise and
increase gear load carrying capacity.
Uses serrations on gear cutter teeth’s that
are quite rough like sand paper and
remove away the metal concentrations
Gear grinding
High class hardened gears are ground
It is finishing process used to remove
considerable amount of metal after heat
treatment process.
Gear burnishing
Used to improve the surface finish and
uniformity of gear this process is used before
and prior to the hardening process.
The unhardened gear is rolled with ample of
lubricant along with several burnishing gears
of high accuracy. The pressure of teethes has
work-hardening effect and smoothes out
irregularities
Tooth profile and pitch are not corrected in
this method.
Gear lapping
The lap is a cast iron gear with same normal
pitch and pressure angle as the gear to be
finished.
The lap meshes with gear to be finished at
some particular angle so that the centre lines
of both are not parallel
Due to this sliding occurs and the lap is
coated with abrasive paste so that when it
meshes with gear the grinding paste removes
high spots on the gear
As with the lap, the softer gear(lap) suffers
less damage and may be used several times.
Gear Honing
After heat treatment, this process helps in
reducing gear noise and finish the tooth profile.
It corrects heat treatment errors.
A gear tooth HONE is an abrasive embedded
plastic helical gear which resembles gear shaving
machine.
The work gear is meshed in cross with HONE.
There is no in-feed mechanism and the honing
tool drives the work gear while it moves back and
forth parallel to work gear axis.
Gear tooth honing can be carried out with a
constant pressure between the gear tooth and
HONE
Broaching
Process of machining a surface with special tool
called broach.
A broach is a tapered bar into which teeth have
been cut so as to produce a desired contour in
work piece by a single stroke.
Broaching is similar to shaping but instead of
single point cutting tool advancing slightly after
each cutting stroke across the work, the broach is
a long tool with many cutting teeth.
Each teeth removes a pre-determined amount of
metal in a pre-determined location of cut.
Polishing
Polishing is done with an abrasive grains
to remove:
i)scratches
ii)tool marks
iii) other similar irregularities produced
on the work surface from previous
machining operations.
Buffing
Buffing is the final operation to improve
the polish of metal.
In this the rubbing action is more gentle
than the vigorous cutting employed in
polishing.
It is used to obtain flat reflective surfaces.
Super finishing
It is also called micro-finishing process
that produces a controlled surface
condition on parts which is unobtainable
by any other method.
It removes chatter marks.
Removes fragmented smear metal from
the surface of a dimensionally finished
part.
Produces the ultimate in refinement of
metal surfaces.

You might also like