GEAR

MANUFACTURING

Machining Casting Other

- Hot Rolling
- Stamping
- Powder
Metallurgy
Gear Gear Gear - Extrusion
Gear Shaping
milling Hobbing Broaching - Coining

Sand Casting Die Casting

Gear machining – form milling
(single gear tooth cutter)

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Gear machining – form milling

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GEAR BROACHING:
•Broaching tool is used in vertical broaching machine.
•Speedy and accurate process.
•Tooth space is produced in single stroke
•More blanks can be mounted at a time.
•Blank is indexed after producing each tooth.
Advantages:
•Finished gears can be obtained.
•Advisable for small gears.
•Advisable for internal gears.
•High production rate.
•Good accuracy.
•Economical
Disadvantages:
•Costly tool
•External gears are difficult to make.
•Different broaching tools are reqd. for gear having diff. modules.
•Not preferable for bevel gears.
GEAR HOBBING: •It is gear generating method.
•Fast and accurate.
•Hob(like worm cutter) is rotary
tool on which single or multi
start threads are cut.
•Each thread is having shape of
involute tooth.
•Gear blank is mounted on
table.
•Relative motion between tool
and work piece is obtained by
gear train.
•Gear blank is moved up to
desired depth.
•Hob is moved in axial direction
of blank.
GEAR SHAPING ( GENERATING METHOD):
•Cutter is one kind of gear having
cutting edge.
•Pinion or rack type cutter can be
used.
•Gear blank and cutter are rotated
with adjusted velocity ratio.
•One gear tooth is generated by one
cutter tooth.
•Cutter is axially reciprocated with 50
stroke/min.
•Reciprocating movement is
dependent on face width.
•Cutter is also reciprocated in radial
direction to provide full depth mean
while blank remains steady.
GEAR SHAPING ( GENERATING METHOD):

Rack type cutter is also used, in

which blank is rotated and cutter
is provided longitudinal motion.

Advantages:
•Spur, helical, rack, internal gears can be manufactured.
•Cutter is universal for same pitch and it does not depend on numbers of teeth.
•Advisable for mass production
Disadvantages:
•Production rate is low compared to hobbing
•Helical guide is required for helical gear.
•Low rigidity.
•Sufficient undercut are required.
GEAR FINISHING METHODS:

Gear shaving:
- Rack type
- Rotary type
-In rack type, shaving tool
is kept below gear and
reciprocated.
-Grooves are made on
cutter.
-In rotary type, grooves
are made on gear shaped
cutter.
GEAR FINISHING METHODS:
Gear Grinding:
1.) Form grinding
-Involute shaped grinding disk is
used to finish each teeth one by
one.
-Indexing mechanism is used to
rotate blank.
-Sometimes two disk wheels are
used to reduce time.
2.) Generation Grinding
-Spiral, bevel gears are grinded
by this method.
-Grinding wheel is also moved in
tooth space.
3.) Grinding by threaded wheel
-Similar to hobbing
-Grinding wheel is having helical
threads.