GEAR
MANUFACTURING
INTRODUCTION
• Gears transmit power or motion mechanically between
parallel,intersecting or nonintersecting shafts.
• most important mechanical elements, they operate at
almost unlimited speeds under a variety of conditions.
• Millions are produced each year in different sizes that
varies from few mm to 30 ft in diameter
1.GEAR THEORY AND TERMINOLOGY
• Gears are modifications of wheels
• Gear teeth or pegs
-to prevent slipping and to assure that their relative motions are
constant
-modern gears have teeth produced by machining or forming teeth
on the outer portion of the wheel
Gear teeth nomenclature
• Pitch circles
-corresponds to the diameter of the wheel
-must be tangential with each other to for two gears to operate
pitch diameter (PD)
-design calculations relating to gear performance are based on pitch
diameter
pitch point
- When a pair of gears are operating in mesh, the point of tangency
between the two pitch circles
Tangent pitch circles between two gears produce
a pitch point
Important tooth elements
• Addendum: The radial distance for which the tooth profile
is extended outward beyond the pitch circle from the pitch
circle
• Dedendum: The radial distance for which the tooth profile
is extended inward from the pitch circle from the pitch
circle
• Pressure Angle: The angle formed between the Line of
Action and a line tangent to the Pitch Point.
• Tooth Thickness: The thickness of the gear tooth
measured along the Pitch Circle.
• Circular Pitch: The length of the arc along the Pitch
Circle between corresponding points of adjacent teeth.
• Face Width: The width of gear tooth measured axially.
• Tooth Face: The mating surface of a gear tooth between
the addendum circle and the pitch circle.
• Tooth Flank: The mating surface of a gear tooth
measured between the pitch circle and the base circle.
2.GEAR TYPES
• Spur Gear
• Helical Gear
• Double Helical Gear
• Herringbone Gear
• Bevel Gear
• Worm Gear
• Hypoid Gear
SPUR GEAR
• Spur gears transmit power through
shafts that are parallel. The teeth of the
spur gears are parallel to the shaft axis.
This causes the gears to produce radial
reaction loads on the shaft, but not axial
loads. Spur gears tend to be noisier
than helical gears because they operate
with a single line of contact between
teeth. While the teeth are rolling
through mesh, they roll off of contact
with one tooth and accelerate to contact
with the next tooth.
HELICAL GEAR
• Helical gears have teeth that are oriented
at an angle to the shaft, unlike spur gears
which are parallel. This causes more than
one tooth to be in contact during operation
and helical gears are capable of carrying
more load than spur gears. Due to the load
sharing between teeth, this arrangement
also allows helical gears to operate
smoother and quieter than spur gears.
Helical gears produce a thrust load during
operation which needs to be considered
when they are used. Most enclosed gear
drives use helical gears.
DOUBLE HELICAL GEAR
• Double helical gears are a variation
of helical gears in which two helical
faces are placed next to each other
with a gap separating them. Each
face has identical, but opposite,
helix angles. Employing a double
helical set of gears eliminates thrust
loads and offers the possibility of
even greater tooth overlap and
smoother operation. Like the helical
gear, double helical gears are
commonly used in enclosed gear
drives.
HERRINGBONE GEAR
Herringbone gears are very similar to
the double helical gear, but they do not
have a gap separating the two helical
faces. Herringbone gears are typically
smaller than the comparable double
helical, and are ideally suited for high
shock and vibration applications.
Herringbone gearing is not used very
often due to their manufacturing
difficulties and high cost.
BEVEL GEARS
• Bevel gears are most
commonly used to transmit
power between shafts that
intersect at a 90 degree angle.
They are used in applications
where a right angle gear drive
is required. Bevel gears are
generally more costly and are
not able to transmit as much
torque, per size, as a parallel
shaft arrangement.
WORM GEARS
• Worm gears transmit power
through right angles on non-
intersecting shafts. Worm
gears produce thrust load and
are good for high shock load
applications but offer very low
efficiency in comparison to the
other gears. Due to this low
efficiency, they are often used
in lower horsepower
applications.
HYPOID GEAR
• Hypoid gears look very much
like a spiral bevel gear but
they operate on shafts which
do not intersect, which is the
case with a spiral bevel gear.
In the hypoid arrangement
because the pinion is set on a
different plane than the gear,
the shafts are supported by
the bearings on either end of
the shaft.
3.GEAR MANUFACTURING
• Blanking
• Gear Cutting
• Heat Treatment
• Grinding
BLANKING
• It refers to the initial forming or machinig operations that
produce a semifinished part ready for gear cutting,starting
from a piece of raw material
• Good quality blanks are essential in precision gear
manufacturing
GEAR CUTTING
• or machinig operations can be divided into opeartions
executed prior to heat treatment
• when the material is still soft and easily machinable and
after heat treatment,performed on parts that have
acquired high hardness and strength.
HEAT TREATMENT
• heating is a process which uses alternating current to
heat the surface of a gear tooth. The area is then
quenched resulting in an increase in hardness in the
heated area. It is typically accomplished in a relatively
short period of time.
• gives the material strength and durability to withstand high
loads
GRINDING
• A gear-cutting method in which gears are shaped by
formed grinding wheels and by generation; primarily a
finishing operation.
4.GEAR MACHINING
• Gear Milling
• Broaching
• Hobbing
• Gear Shaping
• Bevel Gear Cutting
• Cold roll Forming
GEAR MILLING
• This is one of the initial and best known
and metal removal process for making
gears. This method requires the usage of
a milling machine. It is also to be noted
that this method can produce nearly all
types of gears. The method involves the
use of a form cutter, which is passed
through the gear blank to create the
tooth gap. This method is right now used
only for the manufacture of gears
requiring very less dimensional accuracy.
To put it correctly this method is currently
outdated.
BROACHING
• Broaching is a machining
process that uses a toothed
tool, called a broach, to
remove material. There are
two main types of broaching:
linear and rotary. In linear
broaching, which is the more
common process, the broach
is run linearly against a
surface of the workpiece to
effect the cut
HOBBING
• Gear Hobbing is a continuous
generating process in which the tooth
flanks of the constantly moving work
piece are formed by equally spaced
cutting edges of the hob. The main
advantage of this process is its
versatility to produce a variety of gears
including Spur, Helical, Worm Wheels,
Serrations, Splines, etc. The main
advantage of the method is the higher
productivity rate of the gears.
GEAR SHAPING
• Gear shaping is a generating
process. The cutter used is virtually
a gear provided with cutting edges.
The tool is rotated at the required
velocity ratio relative to the gear to
be manufactured and any one
manufactured gear tooth space is
formed by one complete cutter
tooth. This method can be used to
produce cluster gears, internal
gears, racks, etc with ease, which
may not have the possibility to be
manufactured in gear hobbing.
BEVEL GEAR CUTTING
• Bevel gear cutting is a very
specialized area in the field of gear
cutting. This involves a special type
of machine for each variety of the
bevel gear to be manufactured.
Some of the bevel gear types along
with the type of machines required
are Gleason, Oerlikon, Hypoid,
Zerol, etc. Each type of bevel gear
is always manufactured only on the
corresponding type of machine
against its name. The tooling
required also tends to vary based
on the type of gear.
COLD ROLL FORMING
• Roll forming is a continuous process
that employs a series of paired roll
tools to progressively shape a flat
strip of metal into a desired profile.
The process of progressively shaping
the strip is called 'Flowering' as
gradual change in shape appears on
a continuous strip as it passes
through different stages of the
process.
.
5. GEAR FINISHING
• Gear Shaving
• Gear Rolling
• Gear Grinding
• Gear Lapping
6.GEAR INSPECTION
• Gear inspection is an important procedure for
checking not only the overall quality of the
manufactured gear, but it also provides insights to
the efficiency and level of control of the
manufacturing process. It will ensure that the parts
are made to meet quality standards, as well as
customer demands.
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