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    Naseem Khan
    This document discusses different methods for manufacturing gears, including forming methods like casting, molding, and extrusion, as well as machining methods like milling, hobbing, and shaping. It describes various types of gears that can be manufactured and the appropriate production methods for each, such as sand casting for low precision gears. Key gear manufacturing methods include gear milling, gear hobbing, gear shaping, and bevel gear cutting. Forming methods produce gears all at once in a mold or die, while machining allows for higher accuracy.

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    TO PIC: Synopsis

    Uploaded by

    Naseem Khan
    27 views11 pages
    This document discusses different methods for manufacturing gears, including forming methods like casting, molding, and extrusion, as well as machining methods like milling, hobbing, and shaping. It describes various types of gears that can be manufactured and the appropriate production methods for each, such as sand casting for low precision gears. Key gear manufacturing methods include gear milling, gear hobbing, gear shaping, and bevel gear cutting. Forming methods produce gears all at once in a mold or die, while machining allows for higher accuracy.

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    This document discusses different methods for manufacturing gears, including forming methods like casting, molding, and extrusion, as well as machining methods like milling, hobbing, and shaping. It describes various types of gears that can be manufactured and the appropriate production methods for each, such as sand casting for low precision gears. Key gear manufacturing methods include gear milling, gear hobbing, gear shaping, and bevel gear cutting. Forming methods produce gears all at once in a mold or die, while machining allows for higher accuracy.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    27 views11 pages

    TO PIC: Synopsis

    Uploaded by

    Naseem Khan
    This document discusses different methods for manufacturing gears, including forming methods like casting, molding, and extrusion, as well as machining methods like milling, hobbing, and shaping. It describes various types of gears that can be manufactured and the appropriate production methods for each, such as sand casting for low precision gears. Key gear manufacturing methods include gear milling, gear hobbing, gear shaping, and bevel gear cutting. Forming methods produce gears all at once in a mold or die, while machining allows for higher accuracy.

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    of 11

    SYNOPSIS

    TO
    PIC- Different types of gear manufacturing methods

    (MEC-205)

    SUBMITTED BY: SUBMITTED TO:


    MANISH KUMAR Mr. DIGVIJAY SINGH
    PROGRAMME NAME &
    CODE: B-TECH (ME-152)
    SECTION: B4912
    ROLL NO.: B31
    REDG NO.: 10902716
    GEAR MANUFACTURING

    Contents
    Introduction
    Forming
    Casting

    Sand casting
    Die casting
    Injection molding
    Extruding
    Cold drawing
    Stamping
    Preforming
    Forging

    Machining
    Roughing
    Form milling
    Rack generation
    Hobbing
    Finishing
    Shaving
    Burnishing
    Gear Menufacturing Machines

    Gears play a prominent role in mechanical power transmission.


    Manufacturing of gears is a very interesting area involving
    various methodologies and varies with the type of gears to be
    produced. This article describes the various methods of
    manufacturing methodologies followed for each type.
    INTRODUCTION
    Gear manufacturing can be divided into two categories namely
    forming and machining as shown in flow chart in Fig 5.1.
    Forming consists of direct casting, molding, drawing, or
    extrusion of tooth forms in molten, powdered, or heat softened
    materials and machining involves roughing and finishing
    operations. They are discussed in the different sections of this
    chapter.

    Gear Manufacturing
    Gear manufacturing basically is categorised based on the type
    of gear to be manufactured. The types of gears can be
    classified as follows:

    1. Spur
    2. Helical
    3. Worm Gears
    4. Bevel Gears

    The manufacturing methodology involved for manufacturing of


    the above types of gears defines the types of machines to be
    used. The various production methods for producing the above
    mentioned gears by machining are as follows.

    a) 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.

    b) Gear 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.

    c) 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.

    d) 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.

    Categories of gear manufacturing process


    Characteristics: In all tooth-forming operations, the teeth on
    the gear are formed all at once from a mold or die into which
    the tooth shapes have been machined. The accuracy of the
    teeth is entirely dependent on the quality of the die or mold
    and in general is much less than that can be obtained from
    roughing or finishing methods. Most of these methods Machine
    Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute
    of Technology Madras have high tooling costs making them
    suitable only for high production quantities. The various
    forming techniques are discussed below in detail:
    Characteristics: In all tooth-forming operations, the teeth on
    the gear are formed all at once from a mold or die into which
    the tooth shapes have been machined. The accuracy of the
    teeth is entirely dependent on the quality of the die or mold
    and in general is much less than that can be obtained from
    roughing or finishing methods. Most of these methods Machine
    Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute
    of Technology Madras have high tooling costs making them
    suitable only for high production quantities. The various
    forming techniques are discussed below in detail:

    Casting
    Sand casting, die casting and investment casting are the
    casting processes that are best suited for gears and are shown
    in fig 5.2. They are explained in the following sections:
    The characteristics of sand cast gears are,
    1
    Cheaper low quality gear in small numbers

    The tooling costs are reasonable

    Poor Surface finish and dimensional accuracy

    Due to low precision and high backlash, they are noisy.

    They are suited for non- critical applications


    Applications:
    (without finishing operation)
    Sand casting is used for gear manufacture which are used in
    variety of applications such Machine Design II Prof. K.Gopinath
    & Prof. M.M.Mayuram Indian Institute of Technology Madras
    as for toys, small appliances, cement-mixer barrels, hoist
    gearbox of dam gate lifting mechanism, hand operated crane
    etc.,
    Applications:
    Gears that are die cast are used in instruments, cameras,
    business machines, washing machines, gear pumps, small
    speed reducers, and lawn movers. Fig. 5.3 shows gears that
    Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian
    Institute of Technology Madras

    Characteristics:
    The characteristics of gears that are manufactured by
    investment casting are,
    1
    • Reasonably accurate gears

    • Applicable for a variety of materials

    • Refractory mould material

    • Allows high melt-temperature materials

    • Accuracy depends on the original master pattern used for


    the mold.

    • Accuracy similar to die-cast gears

    • Material properties can be Tailor made

    • Typically suited for small sized gears

    Economical for large lot size only


    •

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