Different gear combinations are used to give the smooth running, the lower fuel consumption, and the optimum driving comfort. Gear manufacturing lecture by allan arch at fiu mechanical engineering, miami, florida duration. Gear technology septemberoctober 2006 the journal of gear manufacturing. This article describes the various methods of manufacturing methodologies followed for each type of gear.
Gear design national broach and machine division,of lear siegler, inc. Definitions diametral pitch, p nd module m is reciprocal of p dn circular pitch. Gear manufacturing processes free download as pdf file. If the mating gear has more teeth than the pinion, that is. A material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. Gears play a prominent role in the mechanical power transmission. In linear broaching, which is the more common process, the broach is run linearly against a surface of the workpiece to effect the cut. However with powder metallurgy process it is slowly getting into industry now for specific application. It is true shape generation process in that the gear shaped tool cuts itself into mesh with the gear blank. Paul,department of mechanical engineering, iit kharagpur.
Manufacturing of gears is a very interesting area involving various methodologies and varies with the type of gears to be produced. Non traditional manufacturing processes an overview introduction nontraditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be. Non traditional manufacturing processes an overview. Oct 22, 2008 lecture series on manufacturing processes ii by prof. Lecture 26 broaching principle systems and applications. A gear box transmits the engine power to the driving wheels with the help of different gearing systems.
Gear manufacturing can be divided into two categories namely forming and machining as shown in flow chart. Rack and pinion sets a special case of spur gears with the gear having an infinitely large diameter, the teeth are laid flat. Double helical gear this is a gear with both lefthand and righthand helical teeth. Unit 6 gear generation and finishing gear generation. From the beginning of the century, the demand for better productivity of gear manufacturing. Lecture 5 gear manufacturing contents of the lecture gear manufacture can be divided into two categories, forming and machining. Classification of manufacturing processes for producing of products materials are needed. Jul 25, 2015 manufacturing technology gear shaping process gear shaping uses 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.
Blodgett senior design consultant, lincoln electric co. Gear manufacturing methods engineering study materials, gear manufacturing methods, gear manufacturing process in hindi, gear manufacturing process pdf, gear manufacturing process nptel, gear. To meet the strenuous service conditions the gears should have. The number of teeth for spur gears is given by where k 1f fll1 for fulld tht th08f tbt th d ldepth teeth, 0. Manufacturing processes i nptel online videos, courses. What are the sources of errors in gears and measurement of. Master thesis erasmus mundus master of mechanical engineering setup of the manufacturing process and economic study of the gear box for industrial vehicle. Gear machining cnc machining is actually used in the manufacturing of gears with extreme precision and accuracy. M arc on pitch circle from flank of one tooth to other tooth. Classification of manufacturing processes engineers gallery.
Gray cast iron nodular and ductile cast iron good casting property carburizing steel nitride steel bronze nonmetals as plastics, reinforced laminates noiseless operation, cheaper 4. It is a very important manufacturing processes that can not only help the manufacturing process but can also improve product, its performance, and its characteristics in many ways. Generally, passenger car transmissions are provided with 45 forward speeds and one reverse speed. Depending upon the type and accuracy of motion desired. Milling is a basic machining process which uses the relative motion between a rotating, multiedge cutter and a workpiece to cut individual gear teeth. The grinding wheel rotates at 3600 rpm, has a diameter d of 150 mm, thickness b of 25 mm, and c 5 grains per mm2. Introduction to manufacturing processes introduction. Introduction to gear, the various types of gear, gear terminology and gear manufacturing processes.
Generally, process improvements are made regularly with new efficiencies embedded within the process. Connecting rods manufacturing improvements and process planning tolerance chain analysis and training material silvia garde gonzalez master thesis 2015 kth royal institute of technology. Nptel course on manufacturing processes i, pradeep kumar et al. Forming consists of direct casting, molding, drawing, or extrusion of tooth forms in molten, powdered. Metal casting is a labour intensive process automation. Length wise gashes or flutes are cut across the spiral to form cutting edges 37. In this process a hollow broaching tool, called the pot, is used to cut the gear teeth. Gear machining is used to manufacture a number of products, including internal gears, worm gears, sprockets, spur and helical gears. The smallest number of teeth on a spur pinion and gear, onetoone gear ratio, which can exist without interference is np.
Instructional objectives i manufacturing process ii. Gear technology, the journal of gear manufacturing issn 07436858 is published bimonthly by randall publishing, inc. However, manufacturing considerations limit the profiles to simple curves belonging to the circle group, or those which can be readily generated or f. Setup of the manufacturing process and economic study of the. In this process, a pinion shaped cutter is used, which is mounted with its axis vertical and is reciprocate up and down. Gear generation and unit 6 gear generation and finishing finishing operations operations structure 6. Design actual gear systems, including specifying materials, manufacturing accuracy, and other factors necessary for complete spur gear design.
This shaving processcauses very fine chips are cut from the tooth surface process requires less than 1 minute. Hobbing process is carried out on gear hobbing machine using hob as tool. Find materials for this course in the pages linked along the left. Module 3 selection of manufacturing processes nptel. Normally, either soft gear process dynamic or hard gear process dynamic is being aimed.
The influence of materials and geometry types of gears gears play an essential role in the performance of the prod. To understand the gear manufacturing or gear cutting process it is necessary to understand gear. Gear cutting me 312 manufacturing technologyvikrant sharma, mechanical engineering department. Metal casting processes indian institute of technology guwahati. Specifically, hobbing, milling, and shaping are defined, as well as the four primary types. Norton, design of machinery introduction to cam design. Gear technology marchapril 2004 35 gear heat treatment. Manufacturing technology gear shaping process gear shaping uses 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. Gear manufacturing processes gear transmission mechanics.
Gear manufacturing an overview sciencedirect topics. It includes detailed information to gain insight into the manufacturing processes which are new, unconventional and list out the the. Hypoid gear this is a deviation from a bevel gear that originated as a special development for the automobile industry. Worm gear sets consists of a helical gear and a power screw worm, used to transfer motion between nonparallel and nonintersecting shafts. Now, if we look into the manufacturing process of processing then first of all the. Gear steels come in grades 1, 2, and 3 as classified by the american gear manufacturing association agma. The second graph plotted is the range of thickness is plotted. Introductiona gear is an important machine elements which is used to for transmission of power or motion or both from one shaft to other. Automobiles, gear boxes, oil engines, machine tools, industrial machinery, agricultural machinery, geared motors etc. Most of the conventional miniature gears manufacturing processes produce miniature gears quality ranging between 9 and 12 din standard and require secondary finishing process to achieve the desired gear quality, i. One important application of form milling is in gear manufacturing. Lecture 5 gear manufacturing nptel indian institute of. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. The production process required for gear manufacturing covers a lot of ground, but general examples which can be given include cutting of materials with cutting machines, processing of materials with lathes, cutting of cylindrical gear teeth with hobbing machines, cutting of rack teeth with rack panels, cutting of internal gear teeth with gear.
Gear manufacturing has been one of the most complicated of the metal cutting processes. Broaching is a machining process that uses a toothed tool, called a broach, to remove material. Process equipment tends to be more complex thus problems can be more complex designing a product wheel for a process making sheet goods of various widths, thicknesses, tensile strengths, and densities is more complex than developing a mixedmodel schedule for a process making gear pumps. Pdf nontraditional manufacturing processes by gary f. Gear wheels shaving the gear and the cutter are run in mesh with their axes crossed at a small angle.
Mechanical engineering manufacturing processes ii nptel. Gear manufacturing process dynamics are undergoing a major breakthrough in last two decades. Jan 01, 20 worm gear sets consists of a helical gear and a power screw worm, used to transfer motion between nonparallel and nonintersecting shafts. I the term am encompasses many technologies including subsets like 3d printing, rapid prototyping rp, direct. Sparkerosionbased processes can achieve gear quality up to din. Again, it can be regarded as a portion of a helical gear with infinite radius. Gears can be manufactured by a variety of processes, including casting, forging, extrusion, powder metallurgy, and blanking. Forming consists of direct casting, molding, drawing, or extrusion of tooth forms in molten, powdered, or heat. Gear manufacturing methods engineering study materials. Download the seminar report for gear manufacturing processes.
This process is the most versatile of all gear cutting processes. Extra attention has been paid to the effects of friction and process planning in the result of process loads and also on the gear quality. Determine allowable force on gear teeth, including the factors necessary due to angle of involute of tooth shape and materials selected for gears. Machining is the manufacturing process by which parts can be produced to the desired. This is a linear shaped gear which meshes with a helical gear. Lecture notes design and manufacturing ii mechanical. This process is usually done by an experienced machinist.
Lecture series on manufacturing processes ii by prof. Miller welding design engineer, lincoln electric co. As a general rule, however, machining is applied to achieve the final dimensions, shape and surface finish in the gear. Continuous process improvement is a critical part of lean manufacturing. Solutions being sought are not corrective but preventative. Rajiv shivpuri professor of industrial, welding, and systems engineering, ohio state university. You are grinding a steel, which has a specific grinding energy u of 35 wsmm3. Examples of parts made using shell molding include gears, valve bodies, bushings. Also, the cutter and the gear blank both are rotated slowly about their own axis. Jun 12, 2018 gear manufacturing methods engineering study materials,gear manufacturing methods,gear manufacturing process in hindi,gear manufacturing process pdf,gear manufacturing process nptel,gear. Part of the fundamental manufacturing processes video series, this program introduces many primary gear terms and definitions, including involute curve, base. Roughing processes include milling the tooth shape.
The thesis structure is based on four published papers, and some additional results from. During the rotation the gear is reciprocated longitudinally across the cutter. Home tags manufacturing process hajra choudhary pdf download. Gear design national broach and machine division,of. It is therefore important to know the characteristics of the available engineering materials. Iron is good because of its castability and wear characteristics. Explain what a cam is, how it is used, and the typical types of cams. Madsen manager, industrial products engineering, neenah foundry co. Box 1426, elk grove village, il 60007, 847 4376604. Gears are used extensively for transmission of power.
Unit 6 gear generation and finishing gear generation and. Production processes of gear rack is a page to introduce production process of gear rack done in khk facotory. Singhmelkotecolton honing and superfinishing honing tool used to improve the surface finish of bored or ground holes. Lecture series on manufacturing processes i by prof. Schematic illustrations of the superfinishing process for a cylindrical part. Periodical postage paid at arlington heights, il, and at additional mailing office usps no. Hob is a cylinder on the surface of which a continuous thread has been cut having the cross section of involutes gear teeth. A gear can be defined as a toothed wheel which, when meshed with another toothed wheel with similar configuration, will transmit rotation from one shaft to another. Broaching is a machining process for removal of a layer of material of desired width and depth. The bulk of power transmitting metal gears of machinery are produced by machining process from cast, forged, or hot rolled blanks. Classification of metal removal processes and machine tools.
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