Imperial Journal of Interdisciplinary Research (IJIR)

Vol-3, Issue-7, 2017

ISSN: 2454-1362, http://www.onlinejournal.in

Parametric Analysis of Gear Hobbing

Process by Using TiN and AlCrN
Coated M 35 Hob
S. A. Dharurkar1, R. A. Kathar2 , M. S. Kadam3 & A.L.Chel4
1
Dept. of Mech. Engg., MGM’s Jawaharlal Nehru Engineering College, Aurangabad

Abstract: Gear hobbing process is the most common

type of manufacturing process used for gears
generation. Majority of gears are used for power
transmission in Automobile and industrial machines.
The tool material used for manufacturing of hub is
M35 high speed steel (HSS). These gear hobs are
generally coated by PVD coating. The objective of
this research paper is parametric analysis of process
parameters of gear hobbing for two different coating
materials like TiN and AlCrN. In this analysis the
investigation was carried out for process parameters
like the effect of variation on the size of span width
and P.C.D run out. Experimentation is carried out by
using Response Surface Methodology (RSM) and
Experiments are conducted on MISTIBUSHI - 250 Figure 1 Process of Gear Hobbing
CNC Gear Hobbing Machine. The hob teeth behave like screw threads, having a
Keywords: Gear Hobbing, coating materials- AlCrN definite helix angle [3]. During operation the hob is
and TiN, DOE-RSM tilted to helix angle so that its cutting edges remain
square with the gear blank. Gear hobbing is used for
making a wide variety of gears like spur gear,
1. Introduction
helical, hearing-bone, splines and gear sprockets, etc.
In industries the mostly process used for gear Three important parameters are to be controlled in
generation is gear hobbing. [1] In this process, the the process of gear hobbing indexing movement,
gear blank is rolled with a rotating cutter called hob. feed rate and angle between the axis of gear blank
Gear hobbing is done by using a multipoint cutting and gear hobbing tool (gear hob). A schematic
tool called gear hob. It looks like a worm gear diagram of the setup of a gear hobbing machine is
having a number of straight flutes all around its illustrated in Fig. 1. The aims of hob are set at an
periphery parallel to its axis. These flutes are so inclination equal to the helix angle of the hob with
shaped by giving proper angles to them so that these the vertical axis of the blank [4]. If a helical gear is
work as cutting edges. In gear hobbing operation, to be cut, the hob axis is set at an inclination equal to
the hob is rotated at a suitable rpm and the sum of the helix angle of the hob and the helix
simultaneously fed to the gear blank. There is angle of the helical gear. Proper gear arrangement is
synchronization between the rotation rpm of gear used to maintain rpm ratio of gear blank and hob.
blank and gear hob so that for each revolution of gear The operation of gear hobbing involves feeding the
hob, the gear blank rotates by a distance equal to one revolving hob till it reaches to the required depth of
pitch distance of the gear to be cut [2]. Motion of the gear tooth. Simultaneously it is fed in a direction
both gear blank and hob are maintained continuously parallel to the axis of rotation. The process of gear
and steady. The hobbing processes is as shown in hobbing is classified into different types according to
Fig.1. the directions of feeding the hob for gear cutting [5].
2. Literature Survey
Hobs of today suffer from unpredictable wear
making difficult to schedule when they should taken
out for reconditioning. This investigation is aimed to
contribute the fundamental knowledge of wear

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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-3, Issue-7, 2017
ISSN: 2454-1362, http://www.onlinejournal.in

mechanism and wear propagation of hobs used in dry interesistitial solid solution (Ai-AI-N, Ti, AI-N-c,
hobbing. The material AlCrN coated hobs are used in Ck). The third generation (1990) multilayer strucual
actual gear cutting [1]. super lattices (M/MN/M) and (MN/MC/NN) etc. M-
The improvement in the hobbing test design is metallic compound, Fourth generation (2002) Nano
problematic to the very long duration of wear test. laminated structures and nano composite structures,
The application of an analogy process could “Fly nano structures depend with solid compounds as dry
hobbing” has been developed on a five areas milling lubricants. Present generation (2010) DLC and OAJ
machine so as to improve the productivity coating. DLC- Diamond link coating. The properties
Preparation of edge procedure based on the abrasive of PVD coatings for tooling are constantly improved
flow machining technology. In this paper “Fly in order to meet the requirements of new materials
hobbing” method is used. This process is based on and applications. In the comparison with standard
the same kinematic to a hobbing operation, but coating (TiN, TiAlN) where the hardness decrease
involves single tooth. This single tooth simulates the upon annealing to 500-700 degree. Advanced mono-
work of each tooth from a hob. This enables an block AlCrN coatings, multilayer TiAlN/ AlCrN and
easier observation of the wear modes during the nc- (Al,Ti,Cr) N/a –S-1-3 N-4 nano composite
investigation. The objective of this paper was to coatings remain stable up to high temperature of
enhance this fly hobbing test by using quicker and 1100oC. This is the significant advantages of these
cheaper method. In this method hob is endless screw coatings in industrial applications, such as high speed
and gear is wheel. The kinematics both the two is cutting and dry machining where the high
controlled by CNC system. The ratio of rotating temperature are reacted at cutting edge of tool [4].
speed must be controlled accurately [2]. From above literature survey, the gaps were
The wear of high speed steel hobs during hobbing identified related with gear on wear of the cutting
has been studied. The wear mechanisms are strongly tool i.e. hob and various materials [5] e.g. hob of the
influenced by the choice of cutting speed. The material H.S.S., Power metallurgical H.S.S.
microstructure and wear behavior of two high speed (PMHSS) hob.
degrades (M-35 and ASP3025) has been compared. It is found that less work has been reported on the
Roughness, profilometer is used for measuring the effect of coating (Hob) on the process parameters of
gear surface roughness. Two grades of HSS M35 and gear (W/P). Hence, this gap of research work has
ASP3025) are selected for this purpose. been identified for the investigation in this research
Mechanical and structural properties of variable paper.
alloyed TiAlN based hard coatings. There is increase The comparison has been made between two
in industrial uses of modern tools used in cutting coating TiN and AlCrN. Hence, the study narrates
operations today that are coated with PVD hard the focus on the effect of different coated tool on the
coating based on TiAlNcoating shows high hardness, parameters of work piece.
good thermal stability and oxidation resistance which
enhances tool performance in many metal cutting 3. Experimental setup
operations. This paper reports the result of the
comparative investigation of ternary and quaternary Hobbing is a continuous gear generation process
nitride systems with an objective to understand the widely used in the industry. For high or low volume
relationship between the mechanical and structural production of external cylindrical gear. Gear hobbing
properties. Additionally oxidation texts at elevated is one of the major manufacturing processes in the
temperature have been performed to rate this aspect industry. Modern engineering practice is continually
of resistance to the high temperature wear increasing its demands form or e-gearing of old and
environment during metal cutting. A standard new types with a higher and higher degree of
balance cathode arc coating machine. Baker RCS accuracy.
has been used for deposition of various nitrides The traditional gear machining methods hobbing
firms. The crystal structure of these deposited CoTi and shaping has limitations on manufacturer’s ability
Al N coating was examined by XRD, TEN and SEM. to efficiently manufacture gear in small and medium
Oxidation behavior is an important property of hard batches. For a spur gear being cut with a single start
coatings particularly for cutting tool applications. hob, the work piece will advance one tooth for each
This paper describes the effect of certain element to revolution of the cutter. When hobbing a 20 tooth
standard (Ti AI) N coatings [3]. gear, the hob will rotate 20 times, while the work
Latest development in PVD coatings for tooling. piece will rotate once.
This paper presents the recent developments in the Table 1. Specifications of CNC Gear hobbing
field of PVD coating for manufacturing tools. The machine
development of PVD coatings are following steps. Name of machine CNC Hobbing
First generation (1970) Pseudo ceramic materials Model No. GE 25 A
based on binary compounds (TiN, TiC, TiB-2 etc).
The second generation (1985) ternary and quaternary

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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-3, Issue-7, 2017
ISSN: 2454-1362, http://www.onlinejournal.in

Manufacturer Mitsubushi Japan angle. Maximum lead angle for hobs with straight
gashes is usually within 6 to 8 degrees. Sometimes
Mfg.Date August 2012 for high production, hob diameter has to be increased
Maximum OD 250 mm to enable utilization of a longer hob, since very high
length over diameter ratio may undermine the system
capacity rapidly.
Axial Travel 250 mm 4.4 Hob accuracy class selection:
Hob accuracy selection is based on AGMA gear
Radial Travel 210 mm quality, stage of manufacturing and number of starts.
Maximum cutting 6 mm The productivity increases when hobs with greater
number of starts are employed.
module
Main motor 18 kW 4.5 Tool (Hob) material

Machine weight 9500 kg In this experiment tool material i.e. hob material
selection process is very important and play an
important role in quality, as well as cost of the
The profile is formed by the equally paced product.
cutting edges around the hob, each taking successive Generally for hobbings process high speed steel
cuts on the work piece, with the work piece in a (HSS) i.e. tool steels are preferred. Here M 35 (HSS
slightly different position for each cut. Several tool steel) is selected as a hob material due to its
cutting edges of the tool will be cutting at the same properties and cost effectiveness.[2]
time as shown in Fig.2. M 35 is a conventionally manufactured Cobalt
alloyed high speed steel. Various stages of
manufacturing process are chosen and controlled so
that an end product is obtained within a good
structure in terms of carbide size and distribution.
This is the distinct advantage for the finishing tool.
M 35 is characterized by all round applicability and
good machinability [1]
Table 2 Composition of M 35
(HSS tool steel)
Composition C Cr Mo W Co V

% 0.93 4.20 5.0 6.40 4.80 1.80

M 35 is high speed steel suitable for cutting

tools such as broaches, taps, drills, hobs, saws etc. In
terms of performance M 35 is an all-round steel to be
Figure 2. CNC Gear hobbing machine used in cutting conditions where demands for hot
hardness are of importance. These steel pusses on
4. Selection processes parameters
admirable combination of wear resistance and
4.1 Selection of number of starts:
toughness and in these respect superior to the high
The number of starts of the hob depends on
alloyed cold worked steel. [4]
pitch, number of teeth, and stage of manufacturing,
gear quality and divisibility with number of teeth of 4.6 Work piece material
the gear. The material for work piece 20 MnCr5 – chromium
4.2 Selection of number of hob gashes: steel is a commonly used. Material for the
The more numbers of gashes, the more cutting manufacturing of a gear which has outstanding
edges are engaged. Resulting in less cutter load and mechanical properties as far as gears are concerned.
wear. Greater numbers of gashes also increase the [15]
number of enveloping cuts which make the involute Table 3 Composition of 20 MnCr5
smoother. This is especially important when cutting
gears with small numbers of teeth. C% Si% Mn% P% S%
4.3 Selection of hob diameter: 0.172-0.22 0.400-0.03 1.102-1.40 0.025 0.035
Smaller hob diameter usually results in less
cutting time since greater hob RPM can be achieved.
Limiting factors for reducing further both diameters
are usually minimum number of gashes and lead

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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-3, Issue-7, 2017
ISSN: 2454-1362, http://www.onlinejournal.in

4.6 Coating material 5 200 0.7 15.738 37.5 26.39

In this experiment, AlCrN and TiN are selected 6 300 0.7 15.735 38.5 26.37
as coating material for hob. The property comparison
7 260 0.5 15.741 39 26.42
is as shown in Table 4.
8 260 1 15.745 37.5 26.48
Table 4 Coating material properties 9 260 0.7 15.74 38 26.4

10 260 0.7 15.741 37 26.41

Properties AlCrN TiN Coating
11 260 0.7 15.742 38.5 26.4
Coating
Color Blue Gray Metallic Gold 12 260 0.7 15.74 38.7 26.42

Hardness H [GPa] 32 16 13 260 0.7 15.741 40.5 26.42

Friction 0.4 0.6 14 260 0.7 15.742 39.5 26.4
Coefficient
Max Usage 1100 600 Table 5. Process parameters, symbol and their
Temperature range
(degree
centigrade) Process Symbol Unit Range
Parameters
5. Experimental Design Methodology
Design of experiment is a test or series of tests Speed v rpm 250-300
that the input variable (parameter) of a process is Feed s mm/rev 0.5-1.0
changed so that observation and identifying
corresponding changes in the output response can be
verified. 5.3 Determination of Intermediate Level

5.1 Response Surface Methodology: After deciding higher and lower level of each
parameter, to perform the experiments with this two
Response Surface Methodology is an empirical parameters and five levels need to find out
modeling approach for determining the relationship Intermediate Level as given in Table 6.
between various processing parameters and
responses. The RSM is a collection of mathematical Table 6. Parameters and their different levels
and statistical procedures, used for the analysis of
with Coded and Actual values
problems in which the desired response is affected by
several factors. In order to develop the mathematical Parameters
model based on experimental data, a proper planning Levels
of experiments is necessary. The traditional method -2 -1 0 +1 +2
of experimentation, i.e. varying one parameter at a
Speed 200 220 260 280 300
time and studying its effect is considered costly and
time consuming. Hence, the design of experiments (rpm)
(DOE) technique has been selected that requires Feed 0.5 0.6 0.7 0.8 1.0
minimum number of experiments to be conducted.[6] (mm/rev)

1. Selection of Range of parameters

The experimentation was carried out with
inputs like speed, feed and for deciding range of for various speed (rpm) and feed (mm/rev). The
parameters pilot experiments were conducted as experimental data shows corresponding variation in
given in Table 5. the output responses like span size (mm), PCD run
Table 7. Experimental data on ALCrN out (micron), root diameter (mm).
Spee
d Feed span PCD Root
6. Result and discussion
Experimental (rpm (mm/rev size R/O Dia. The experimental results were obtained by
Run ) ) (mm) (micron) (mm) conducting experiments based on DOE by response
1 250 0.6 15.743 38.5 26.4 surface methodology and discussed in this paper.
2 250 0.8 15.742 36.5 26.42
3 280 0.6 15.745 39.5 26.45

4 280 0.8 15.748 38 26.46

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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-3, Issue-7, 2017
ISSN: 2454-1362, http://www.onlinejournal.in

The Fig.3a shows there are the outliners. In the

similar manner, the results for AlCrN coating
material have been obtained for PCD Run out and
Root Diameter as shown in Figs 3(b,c).

Similarly, for second coating material TiN all

three parameters response have been obtained for
span size, PCD Run out and root diameter
respectively as shown in Figs.4(a-c).

Figure 3a. Residual Plots for span size (AlCrN)

Residual plots:
Use to examine the goodness of model Fit in
regression and ANOVA.
Normal probability plot of residuals:
This graph plots residuals versus their expected
values when the distribution is normal. The points in
this plot should generally form a straight line, if
residuals are normally distributed. If the point is far
away from the line then generally appeared to follow Figure 3b. Residual Plots for PCD Run out
the straight line as shown in Fig therefore the
distribution is normal. (AlCrN)
Residual versus Fitted value:
This graph plots residual versus Fitted values. This
plot show a random pattern of residuals on the both
sides of zero. The residuals should be scattered
randomly about zero then that means constant
variance. If point lies far from the majority of points,
it may be an outliner. As shown in Fig plot of span
size variation appears to be randomly scattered about
zero.
Residual versus order of data:
This is the plot of all residuals in order that the data
was collected and can be used to find out non
random error, especially time related effect. This plot
helps to check assumption that the residuals are
Figure 3c. Residual Plots for Root Diameter
uncorrected with each other. The residuals in this
(AlCrN)
plot should fluctuate in a random order around the
center line. This plot used to examine if any
coordination exists between the error terms, co-
relation among the residuals may be existed between
the error terms, co-relation among the residual may
be signified by varied changes in the signs of
adjustment residuals. As shown in Fig it is shown
that there is absence of any non random data and no
evidence exists that the error terms are correlated
with one another.
Histogram of the residuals:
An exploratory tool to show general
characteristics of the residuals including typical
values, spread and shape. A long tail on one side may
indicate a sketch distribution. If one or two bars far
away from the other, those points may be outliner.

Figure 4a. Residual Plots for span size (TiN)

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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-3, Issue-7, 2017
ISSN: 2454-1362, http://www.onlinejournal.in

high heat resistance capacity and themes coefficient

i.e. AlCrN is suggest for better results.

6.2 PCD Runout

Pitch circle diameter run out is an important
parameter in gear. PCD is the diameter of a circle
which will produce the same motion as the toothed
gear wheel it is an imaginary circle of gear the rolls
without slipping over the circle of its mating gear. It
will give the periodic vibration during the each
revolution of gear. This will give the tooth failure in
the gear. Though gears are always used in a pair i.e.
mating components so this variation in the run out can
Figure 4b. Residual Plots for PCD Run out (TiN)
cause the failure of the gear assembly and create a
noise during operation.

There are several factors like accuracy of blank,

setting of hob, fixture run out, machine vibration,
quality of cuter etc. which can affect the PCD run out.
PCD run out is mainly depends upon the quality of
cutting edge of cutter. It is concluded that by using
the AlCrN coated hob variation in the PCD run out is
controlled as compared to TiN coated hob. Hence it is
recommended that the AlCrN coated hob can give the
better tool life, less variation in the PCD run out.

6.3 Root diameter

Root diameter is the diameter of a circle around
Figure 4c. Residual Plots for Root Diameter (TiN) the gear tooth spaces. Root diameter measured at the
base of the tooth. The gear tooth i.e. described by the
6.1 Span Size intersection of the involute with the root diameter i.e.
In gear, tooth thickness is very much bottom of tooth and outer diameter of tooth.
important factor. For Span measurement is one of the
methods by means of which tooth thickness is If the root diameter is less than the base
measured. diameter, these tooth are described as a undercut
Span measurement of gear is a measure over a whenever there is variation in the root diameter of the
number of teeth made, by means of a special tooth gear it will create a problem during the operation
thickness micro meter. The value measured is the through it is meshed with other gear. So it is
sum of normal tooth thickness on the base circle and recommended that there will be controlled variation in
normal pitch. the size of the root diameter for the smooth operation
If there is a more variation in tooth as well as life of the assembly. It is observed that there
thickness during machining of gear because of that is less variation in the process while the hob is coated
excessive separating forces may create which may with the AlCrN coating than TiN and hence it is
cause the bearing failure and also failures related to recommended.
surface fatigue and in some cases bending failure
because of that it is very much important to not only 7. Conclusions
control the size but also minimize the variation in
tooth thickness. Thus it becomes very critical The following key conclusions for the
parameter. In this work the experiments are investigation on different gear hob coating materials
conducted by using two different coatings on M-35 are drawn:
(H.S.S.) hob under the variable speed, feed 1. Span variation in AlCrN coated hob is 0.01
conditions. mm while in case of TiN coated hob it is
0.03 mm
It is observed that the reading obtained by 2. PCD run out of AlCrN coated hob found to
machining of hob i.e. coated by (AlCrN) give less be within 0.010 mm while in case of TiN
variation than that of TiN coated hob. Thus it is coated hob it is within 0.020 mm
recommended that the higher quality coating having 3. Variation in the size of root diameter when
coated with AlCrN is within 0.1 mm while

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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-3, Issue-7, 2017
ISSN: 2454-1362, http://www.onlinejournal.in

in case of coating material TiN ti is within

0.2 mm

8. Acknowledgements
This work was carried out at Premium Auto
transmission MIDC Shendra, Aurangabad under the
factory expert Mr. Shashank Tak.

9. References
[1] J.Grth,M.Larsson,U.Wilkund,“On the wear of
PVD-coated HSS hob in dry gear
cutting”,Elsevier,wear 266,pp. 444-452

[2]J,Rech Influence of cutting edge preparation on

the wear resistance in high speed dry gear
hobbing,Elsevier ,Wear Vol- 261,505-512

[3] Liu Runai, Lv Ming, Resarch on key technologies

of direct drive gear hobbing machine of dry
cutting,International conference on CMCE
IEEE,Vol.-1,PP.577-580
[4] LIN Chao,GUOQian,study for simulation and
experiment on the mode of cutting forces in high
speed dry gear hobbing,Advance manufacturing
technology,Vol.-1,pp.927-932
[5] Racinko G, Jeremija J, Material selection in gear
hobbing, Journal of technical sciences, pp.389-393
[6] Chan IL Park,Multi-objective optimization of the
tooth surface in helical gear using design of
experiment and the response surface method, Journal
of mechanical science and technology,Vol.-24,
pp.823-829

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