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is currently outdated.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

•