Manufacturing Process

Gear & Shaft Manufacturing

Associate Professor Su-Jin Kim

School of Mechanical Engineering

Gear & Shaft
Manufacturing Processes Gyeongsang National University
© 2011 Su-Jin Kim, GNU
 Powertrain Module of Automobile
Powertrain Module
[모듈 공급업체]
현대모비스
한라공조

Engine
[생산업체]
현대모비스
모토닉, 지코
화신, S&T대우
Transmission
한국프랜지 [생산업체]
SJM, 현대EP 현대위아
S&T중공업
에스엘
경창산업

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Index
1. Introduction of Gear
2. Gear Machining
3. Shaft & Gear Forming
4. Bevel Cutting
5. Bevel Forging

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Gear
• Super, Helical
• Bevel(Straight, Spiral, Hypoid)
• Worm
• Shaft & Spline

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Gear Hob
• Pitch
• Gear Hob

© 2011 정영석, 세일공업

Gear & Shaft
http://ma.gnu.kr/vod/Machining/Gear_Hob_Sim.avi
Manufacturing Processes
Gear Hob Sim (20s)
http://www.youtube.com/watch?v=aCRt6yVhXf0
© 2011 Su-Jin Kim, GNU Bevel Gear Sim (3min)
 Hobbing
• A hob (cutter) is rotated one revolution to transfer each 
tooth profile onto a rotating gear blank.
• Used very often for medium to high  sizes of production 
runs.

Gear & Shaft

Manufacturing Processes
http://www.youtube.com/watch?v=TDzhSaSZrSg Gleason P90 Gear Hobber, 3 min
© 2011 Su-Jin Kim, GNU
 Gear Shaper
• The cutter engages the part on the forward stroke and 
pulls away from the part on the return stroke.

Interference
Gear & Shaft
Manufacturing Processes
http://www.youtube.com/watch?v=Dd9Ekl9DPZg (60s)
© 2011 Su-Jin Kim, GNU http://www.youtube.com/watch?v=CHQ1ZABx68o (140s)
 Gear heat treatment
• Carburzing of Gears
• Induction Hardening of Gears
• Ferritic Nitrocarburizing of Gears

Gear & Shaft

http://www.youtube.com/watch?v=iI7QEI2g0lk
Manufacturing Processes (90s)
© 2011 Su-Jin Kim, GNU
 Gear Grinding
• Gear is grinded after heat treat to give fine finish and 
high accuracy.

Rough grinding CNC gear grinder Finish grinding

Gear & Shaft
Manufacturing Processes
http://www.youtube.com/watch?v=w9x7BjDhxSs Gleason 1500G Titan 10min
© 2011 Su-Jin Kim, GNU
 Gear Machining Process of TIC
Ring Gear
공정 Flow

선삭 수입검사 치절(황삭/정삭) 열처리 내경정삭

Pinion Gear
공정 Flow

선삭 수입검사 치절(황삭/정삭/정삭) 열처리 외경 완성 연마

래핑/Test
공정 Flow
(Set화)
Gear & Shaft
Manufacturing Processes
래핑 디버링 / 세척 TEST
© 2011 Su-Jin Kim, GNU
 Shaft & Gear forming of KMC

© 2011 김홍철 KMC

Gear & Shaft
Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Shaft & Gear forming Process
FORMER Coil FORMER Annealing Shot Blast

Lubrication Forging Turning MCT

Rolling 고주파 열처리 Grinding

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Forming

CUTTING UPSET BACKWARD FORWARD

Basic Forming Process

PIERCING

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU TRIMMING
 Former
5Step FORMER Formed Parts

Gear & Shaft

Manufacturing Processes
http://ma.gnu.kr/vod/Forming/Former_KMC.avi (20s 7Mb)
© 2011 Su-Jin Kim, GNU
 Forging
FEM analysis of Clutch Cold Closed Die Forging

FEM analysis of Helical Gear

Gear & Shaft

Manufacturing Processes
http://ma.gnu.kr/vod/Forming/Forging_Pinion_KMC.avi Forging pinion (29s 4Mb)
© 2011 Su-Jin Kim, GNU
 Rolling
Roll Rolling Rack Rolling

Rack Die

Up-Down of Rack

Gear & Shaft

Manufacturing Processes
http://ma.gnu.kr/vod/Forming/Rolling_KMC.avi Rack Rolling (24s, 6Mb)
© 2011 Su-Jin Kim, GNU
 Induction hardening

Gear & Shaft

http://ma.gnu.kr/vod/Forming/Induction_Hardening_KMC.avi
Manufacturing Processes (40s 11Mb)
© 2011 Su-Jin Kim, GNU
 Grinding
Centerless Clyndrical

Gear & Shaft

Manufacturing Processes
http://ma.gnu.kr/vod/Machining/Grinding_Centerless_KMC.avi Centerless (35s 8Mb)
© 2011 Su-Jin Kim, GNU
 Tractor front shaft
6 2 3 4 5
1

10 9 8 7
① Axle Housing
② Connect Case
③ Connect Arm
④ Gear Case
⑤ Gear Housing
⑥ Drive Differential Comp
⑦ 1st Bevel Gear
⑧ Final Bevel Gear
⑨ Final Pinion Gear
⑩ Wheel Shaft
Gear & Shaft
Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Bevel Gear Process
Pinion Gear

Forging Turning Straight Bevel Broaching Carburizing Grinding

Bevel Gear

Forging Turning Straight Bevel Broaching Carburizing

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Bevel Cutting

FACE MILLING NC machining
HARDAC cutter Low productivity

http://www.youtube.com/watch?v=8pXtSWIJ7Ac
Gear & Shaft Bevel Cutting (40s)
Manufacturing Processes
http://www.youtube.com/watch?v=fOLaJMh6DXQ 3-axis Machining (12s)
© 2011 Su-Jin Kim, GNU
 Gear Lapping
• Liquid abrasive compound is feed into the rotating gear 
pairs to smooth teeth surfaces.

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Broach
The broach is run linearly against a surface of the workpiece 
to effect the cut.
BROACH CUTTER

Gear & Shaft

http://www.youtube.com/watch?v=2K45B6tDqsg
Manufacturing Processes Gear Broach
© 2011 Su-Jin Kim, GNU
 Inspection
SPEC.        DATA 
ITEMS RESULT
(JIS 4) (LH/RH)

Pitch Variation 56 46/42 O.K

Pitch Error 73 68/61 O.K

Accumulative
230 101/106 O.K
Pitch Error

Run‐out 100 77 O.K

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Inspection
SPEC.      DATA
ITEMS RESULT
(JIS 4) (LH/RH)

Pitch Variation 62 23/27 O.K

Pitch Error 81 39/45 O.K

Accumulative
250 157/194 O.K
Pitch Error

Run‐out 200 165 O.K

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Inspection

Standard Contact Area Contact Area Inspection

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Bebel Gear Forging

Gear design

Forging simulation

Die Machining

Forging

Inspection

Gear & Shaft

Manufacturing Processes http://www.afdex.com
© 2011 Su-Jin Kim, GNU
 Forging simulation

<12T Bevel gear>

Gear & Shaft

Manufacturing Processes
<20T Bevel gear>
© 2011 Su-Jin Kim, GNU
 Die machining

<12T Bevel gear> <20T Bevel gear>

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Forging

Closed forging die

Press machine
Gear & Shaft
Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Forged bevel gear

<12T Bevel gear> <20T Bevel gear>

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU
 Reference
• Gleason: www.gleason.com
• 세일공업: www.seilkorea.com (정영석, 박창섭)
• KMC: www.kmce.co.kr (김홍철)
• AFDEX: http://www.afdex.com (전만수)

Gear & Shaft

Manufacturing Processes
© 2011 Su-Jin Kim, GNU