GOVERNMENT POLYTECHNIC, SOLAPUR

MAHARASHTRA STATE BOARD OF

TECHNICALEDUCATION,
MUMBAI
2022-2023

Explain in detali which gear manufacturing method is used in modern industries

with respect to job specifications.
A PROJECT REPORT
Submitted By
Roll Full name Enrollment
No no

OTO - GHOSALE ADITYA SHANKAR 2000150546

15
2000150473
OTO -4 ZADE ONKAR SANJAY
2000150551
35 SAMARTH ANIL SWAMI

In Partial Fulfilment of The fifth Semester

Of

DIPLOMA IN ENGINEERING AND TECHNOLOGY

In

MECHANICAL ENGINEERING
Under the Guidance Of

PROF.Ganesh Madgundi
Dr. Hunasimarad S.K. Prof. C. B. Shete
(Principal) (H.O.D)
 CERTIFICATE
MAHARASHTRA STATE BOARD OF
TECHNICAL EDUCATION
Government Polytechnical, Solapur

Roll no. OTO4,OTO15,35 of FIFTH semester of diploma in Mechanical

Engineering of institute Government Polytechnic, Solapur (Code:
0015) have completed the microproject work

Satisfactory under my supervision and guidance in subject

AMP(22563) for the academic year 2022-2023 as prescribe
in the curriculum.

Prof. Prof. C.B. Shete Dr. Hunasimarad S.

Ganesh
Madgundi

(Guide) (H.O.D) (Principal)

Gear Manufacturing Process
There is no single process to gear manufacturing as they require different processes depending on
the type and application.

Generally, gears operate in very strenuous conditions because transmission of power (the actual
purpose of the gear) has several requirements. Firstly, the gears need to be in absolutely perfect
condition. Then, they must always be reliable, have minimal residual stresses, and a little to no
chance of crack propagation.

Naturally, all these requirements are extremely difficult to fulfill. However, no one can deny their
importance. That’s why gear production is a highly specialized field with limited tolerances and
room for error.

This article will take you back to the basics of gear manufacturing concerning the common
materials for industrial gears, the processes that prepare gears, and how gears can sustain all that
load without failing.

Materials Used to Produce Gears

There is no material restriction when it comes to gears. The earliest ones were wooden, and you
can find different material gears throughout the industry. From large industrial scale gears of steel
or iron to small plastic gears in toys. The material combinations are endless.

Nevertheless, the following items are most commonly used in gear manufacturing and gear
forming processes:

Cast iron
Steel
Bronze
Plastics
Gears have very specific criteria for material selection. Depending on the application, whatever
material you choose should have the appropriate tensile strength and endurance.

Additionally, the coefficient of friction is another consideration because gears need constant
contact. Finally, you should also select materials that are easy to process. A strong material with
low manufacturability will be harder to deal with because gears manufacturing requires extreme
precision and accuracy.
The aforementioned materials come with the perfect balance of these properties for their
applications. That’s why you’ll commonly see them in most gears you come across.

RapidDirect can offer all these materials used in the gear manufacturing process. Upload your
design file to get a quotation for your gear project.

Common Gear Manufacturing Processes

Gear production is quite complicated because of the precision it demands. Today, gear
manufacturing is an industry in itself that relies on multiple processes, both traditional and
modern, to ensure the right balance between cost, quality, and operations.

Precision gear manufacturing

Here’s a list of common gear cutting and manufacturing processes along with their apparent
advantages and disadvantages.

1 – Casting
Casting is a simpler process that is predominantly used to prepare blanks or cylinders for gears,
while the teeth are prepared through machining. However, it’s a viable gear manufacturing
process for the whole thing for many applications because of its mass production capability and
relative ease.

There is, however, one area where casting is the most preferred manufacturing method in the
industry. That is the production of very large gears. Machining methods and other gear forming
methods are not that viable in cases of large diameters. Generally, larger gears are almost always
of spur gear type. So, their relative simplicity makes casting a very good option.

Among the most common types of casting methods, shell casting, die casting, sand casting and
permanent mold casting are the most common for gear production. Other methods have limited
use in some applications. However, the aforementioned are the most common in the industry.

2 – Forging
This is another forming process that can give you both blanks and prepared gears depending on
your requirements. Forging is quite viable in cases where you have relatively simple gears.
Gear forging
Theoretically, forging is an excellent gear manufacturing process for heavy-duty applications
because of a simple reason. Forging requires heat treatment, which means that the resulting gear
would have better fatigue properties. However, the tremendous force required for the forging
process limits the size and thinness of this process.
Generally, forging works well for gears within 6 – 10 ft diameter gears. Depending on the type of
forging for example precision forging, you may or may not need to machine the gears in the end.

3 – Extrusion and cold-drawing

This is another gear-forming process that’s both versatile and simpler. In fact, extrusion has a
lower tool expenditure but it doesn’t mean that it’s the most economical process.

Extrusion, as its name suggests, is the process of passing a heated metal profile through a smaller
pre-determined shape. Resultingly, you get a bar of your desired shape with a hardened and
smooth outer surface.

The cold drawing process is very similar to extrusion. There are two differences. Extrusion pushes
the blank through a die drawing pulls it. The other difference is the temperature. Cold drawing
doesn’t heat the billet. Thereby increasing the mechanical properties at the expense of cost.

4 – Powder metallurgy
Powder metallurgy is an advanced process that made significant advancements in recent years.
Today, it’s used for multiple manufacturing processes including gear production.

So, how does powder metallurgy works? From the outlook, it’s quite simple. However, there are
many intricacies involved.

It all starts with metal powder. The first step is to take all the powder is give it a finalized form
that you desire. Once you are done, the next step ensures that the entire setup is quite compact as
it will result in better mechanical properties. Heat the entire setup carefully and you are done.

Powder metallurgy is extremely efficient, simple, and viable for large quantities. You don’t have
to worry about any post-processing as well as the product will be ready to use. However, the
resulting gears can’t bear too much load and there are size limitations as well.

Moreover, the initial cost for any powder metallurgy setup is quite high, which makes it unviable
for any low-volume production.
5 – Blanking
Blanking is a very similar process to extrusion but has limited 3-dimensional capabilities. This
gear forming process uses sheet metal to create the desired shape with the help of multiple dies.
You can produce different types of gears with the blanking process. However, spur gears give you
the best results.

Today, the blanking process of gear production is used by multiple industries for lightweight
applications. For example, office equipment, hydraulics, small medical devices, and other
applications with low load requirements.

6 – Gear Machining
Machining is among the most common gear manufacturing processes because of its versatility.
Traditional machining was quite common for gear cutting and manufacturing but the
advancements of CNC machining have propelled its popularity.

The following 4 gear cutting methods are the most common across the industry.

Hobbing
Hobbing utilizes a conical cutting device called a hob. Both the hob and the workpiece turn as the
hob rotates around the gear blank. So far, external spur and helical gears are the only products you
can create from hobbing.

The process is quite versatile and quick. You can also increase your production rates by
processing multiple stacks together. However, it requires more skills and precision.

Shaping
Shaping is an advanced gear cutting and manufacturing process that develops gears that Hobbing
can’t handle. The cutter can be of any shape like a pinion, rack-shape, or single-point shape. It
looks quite similar to gears and works by cutting into the blank at your required shape. You can
create internal or cluster gears with the shaping process.

Broaching
Broaching is perhaps the quickest method of gear form-cutting. It relies on a multi-teeth tool with
embedded cutters that go deeper than their predecessor. This results in smaller, incremental cuts
that are easier to make and quickly give you the required shape without compromising the
precision.
This gear manufacturing process is typical for internal gears but you can use it to make external
teeth as well. For that, you’ll need a specialized tool for pot broaching that allows you to replicate
the same precision and efficiency.

Milling
This is a basic gear cutting method where you produce individual gear teeth sequentially. It is
however quite versatile, especially when you involve a CNC milling machine. While you can
make any type of gear on a milling machine, the precision of this method leaves a lot to be
desired. That’s why milling is not as common as it was before.

However, the recent developments in the CNC domain and multi-axis have changed things. Gear
manufacturing on milling machines is becoming more and more common. So, things will get even
better with time.

Gear Manufacturing Post-processing

Depending on the gear manufacturing method you used, your gears will need some post-
processing before they are 100% ready. That post-processing can range from heat treatment for
improved fatigue characteristics to dimensional correction and surface finishing.

Here are the 5 most common surface finishing processes that are common in gear production.

Grinding: Just as its name suggests, grinding is a common surface finishing process that gives
you a smooth finish throughout the surface. You can perform it intermittently or continuously, and
it won’t affect the results.
Lapping: This process is for sensitive gears where you need extreme precision. Lapping uses
small abrasive particles to smooth out a surface at low or medium speeds.

Honing: This is another common process that polishes the surface and makes it smooth.
Moreover, you can also correct some minor errors in your tooth geometry
.

Shaving: This process removes extremely thin layers from the surface to achieve a smooth
profile. Shaving is generally expensive, so it’s rarely used in gear production.

Burnishing: In its essence, burnishing is the process of using compression to smooth out the
surface.
Reference
https://www.google.com/
https://www.wikipedia.org/
https://www.rapiddirect.com/blog/types-of-springs-and-applications/