Spur Gears and its manufacturing
at
VMT Pvt. Ltd.
Presented by:
OMKAR DUBEY (1801065)
SHIVAM KUMAR (1801067)
ANSHU RAJ (1801093)
About VMT Pvt. Ltd.
• Established in 2004.
• Manufacturing of tractor lift cover & butterfly
valves is done using CNC machines.
• Recently started manufacturing of CNC
systems and bearings.
• Provides services in manufacturing,
assembling and servicing of various machines
and their tools.
• Manufactured 4000+ conventional machines
and 1200+ CNC machines till date.
Products & Services
• Products:
Conventional Lathe machines
CNC horizontal and vertical Lathe machines
5 axis machines
CNC Grinder
• Services:
Grinding: Surface, Cylindrical, Vertical Segment Grinding
Hobb Sharpening
Gear Hobbing & Shaping
Vertical & Horizontal Boring
Vertical & Horizontal Jig Boring
Vertical & Horizontal Milling
Introduction
Worked in two phases:
The learning phase
The application phase
The Learning phase:
Knowing about the nature of work done in the
industry
Learning the process used for manufacturing of
various tools
Learning about the machines employed
The Application phase:
Manufacturing of Spur Gears by the cutting
process using Conventional Machines
Literature Review
Author Contribution Year
Elaboration of
flexible machining
of various gear
Klocke et al. types and sizes 2014
with one
manufacturing
process.
Effect of contact
ratios on mesh
stiffness of helical
Liu et al. 2014
gears for lower
noise and higher
efficiency design.
Process
description of
complex
Objective
Study the basic manufacturing process of
machine tools and conventional machines used
in the process
Design a Spur Gear and manufacture it in the
industrial workshop
Process Involved
Selection
of Sawing Turning
Material
Pocket
Hobbing Drilling
Milling
Broaching
Process Involved (contd)
• Sawing: A process wherein a narrow slit is cut into
the work piece by a tool consisting of a series of
narrowly spaced teeth, called a saw blade.
• Turning: A machining process in which Lathe rotates
a work-piece about an axis to perform operations like
cutting, sanding, knurling, drilling, turning, etc to
create an object with symmetry about that axis.
• Milling: Machining using rotary cutters to remove
material by advancing a cutter into a work-piece.
• Hobbing: Machining process for gear, splines and
sprockets cutting.
• Broaching: Machining process for creating internal or
external teeth for gears.
Dimensions
Dimension
Characteristics
s
Initial Outer Diameter Before Turning 63 mm
Final Outer Diameter 60 mm
Inner Diameter 12 mm
Outer Base Diameter 54 mm
Inner Base Diameter 15 mm
Thickness 15 mm
Inner teeth 34
Outer teeth 54
Material Mild Steel
Gear Type Spur
Selection of Material
Commonly used materials for
manufacturing of Gears: Cast Iron,
Stainless Steel, Mild Steel, Acetal
Material characteristics kept in mind for
material selection:
High tensile strength to prevent failures against
static loads
High endurance strength to withstand dynamic
loads
Low co-efficient of Friction
Good manufacturability
The material used was Mild Steel
Sawing
Used to cut separate work
parts into two or more pieces
or to cut-off unwanted parts
Narrow slit is cut into the work
piece by a tool consisting of a
series of narrowly spaced
teeth, called a saw blade
Saw blades used were of
Carbon Steel as the lot is
small and costs low
To cut the supplied raw
material into required number
of pieces i.e. 100 parts
Thickness of the stock after Fig. 1: Sawing Machine
sawing: 15mm
Turning
Lathe Machine is used for turning
operation
Cutting operation using a single
point cutting tool to remove
material from a rotating work-
piece to generate a cylinder
Turning operation was done on
3HP/ 3 phase, semi-automatic
conventional Lathe Machine with
max swing over bed: 250 mm Fig. 2: Turning
and max spindle speed: 500 RPM operation
Tool is fed longitudinally to
reduce the diameter
Final outer diameter after
turning: 60 mm.
Milling
Machining operation in which
the work-piece is fed past a
rotating tool with multiple
cutting edges called milling
cutter
Milling operation used is
Pocket Milling, used to create
shallow pockets in flat Fig. 3: Post Milling
surfaces Work-piece
Shallow circular pockets of
5mm on each face of the stock
leaving a thickness of 5mm is
made using Pocket Milling
Drilling
To create round holes in work pieces using
drill bit
Created four Through holes of 6 mm
diameter and four Blind holes of 6 mm
diameter for various uses
Hobbing & Broaching
Hobbing:
Machining process for gear cutting
Teeth are progressively cut into the material by a
series of cuts made by hob
The hob is angled equal to the helix angle of the hob,
which should be less than 10 degrees for Spur Gears
Spur Gears generated are of length of 6 mm
54 outer teeth were generated
Broaching:
Used to create internal teeth in the work-piece
34 inner teeth were created using broaching process
CONCLUSION
Practically applied the manufacturing
processes in the manufacturing of Spur
Gears
After reviewing various processes of Gear
manufacturing: Casting, Machining
processes and use of CNC machines, it was
finally concluded that the Machining
processes are best suitable for the
manufacturing of Spur Gears, keeping in
mind the small lot (100 gears), accuracy,
energy consumption and manufacturing
cost.
REFERENCES
Manufacturing Processes by Mittal et al. (2 nd
Edition) pg.91-119
Klocke et al: Elaboration of flexible machining of
various gear types and sizes with one
manufacturing process, (2014) pg.12-29.
Liu et al: Effect of contact ratios on mesh
stiffness of helical gears for lower noise and
higher efficiency design, (2014) pg.14-22.
Jain et al: Process description of complex
manufacturing process of miniature gears and
secondary finishing to achieve desired gear
quality, (2017) pg. 281-319.
Thank You!
