Manufacturing Technology

Dr. Pradeep Kumar Karsh, Assistant Professor

Mechanical Engineering Department
 CHAPTER-2
Gear and Threads Manufacturing
 Introduction of Thread
General application of thread are as follow:
 Fastening
 Joining
 Clamping
 Transmission of motion and power
 Converting rotary motion to translation
 Different types of Threads

 According to location

 According to configuration

 According to the direction of the helix

 According to form

 According to standard
Different Threads Manufacturing Methods and Tools Involved

1. Thread cutting on a lathe

2. Thread chasing

3. Thread milling

4. Thread whirling

5. Die threading

6. Thread rolling

7. Thread grinding

8. Thread casting
 Thread cutting on Lathe
 To facilitate thread cutting by this process, most of the center lathes and some of
the capstan lathes are equipped with lead screw.

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 Thread chasing
 Method of thread cutting with the help of multi point cutting tool called thread
chaser.
 Form cutting opeartion,with the help of form tool corresponding to the profile of
desire thread.

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 Thread milling
 Thread milling machines
consist of a cutter head
which is provided with
precise lead motion by a
lead screw geared to the
work spindle.

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 Thread whirling
 Fast method for producing threads.
 Widely used in the manufacturing of long, slender components such as lead screws
and extruder screws.

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 Die threading
 Die threading is a machining process for cutting external threads on cylindrical or
tapered surfaces by the use of solid or self-opening dies.

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 Thread rolling
 Thread rolling is a cold forming process for producing threads by rolling the
impression of hardened steel dies on the surface of cylindrical or conical work.
 Because of its high productivity, this method is the most economical of all the
methods of producing threads.

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 Thread grinding
 Thread grinding is applied when: the hardness of the work material makes it
difficult to produce the threads by any other process.
 Where the dimensional and form accuracies are very high.

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 Thread casting
 In casting and moulding threads are directly formed by geometry of cavity in the
mould or die.
 Threads made by sand casting are rough and not used except sometimes in vises
and rough machinery.
 Compare to other casting method lost wax method produce more accurate threads
with good surface finish but it is costly process.
 Due to poor accuracy cast threads are used in such cases where only few threads
are required over short length

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 Different types of Gears
Spur Gear
 In spur gears, teeth are parallel to axis of rotation as shown in figure.
 It transmit power from one shaft to another parallel shaft.

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 Different types of Gears
Helical gear
 The teeth on helical gears are cut at an angle
with axis of gear.
 In helical gears engagement of gear teeth is
gradual as shown in figure.
 This gradual engagement makes helical gears
operate much more smoothly and quietly than
spur gears.

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 Different types of Gears
Rack and Pinion gear
 For converting rotary motion into
linear motion Rack and pinion gears
are used.
 It is a special case of spur gear in
which one gear is having infinite
diameter called "Rack” as shown in
figure.

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 Different types of Gears
Bevel gear
When power is required to be transmitted
from one shaft to another shaft which are
intersecting to each other, bevel gears are
used.
Generally, the angle between two shafts is
90⁰ as shown in figure.

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 Different types of Gears
Worm and Worm wheel
 It is used to transmit power from one shaft
to another shaft which are non-
intersecting and their axes are normally at
right angles to each other as shown in
figure.

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 Forming and Generating Method
Form cutting :

 The forming process involves finish

machining of gears teeth to a
predetermined profile by means of form
cutters or single point reciprocating form
tools.
 Spur, helical, worm and straight bevel
gears can be cut on milling machines with
the help of dividing heads. With proper
attachment, racks can also be cut.

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 Forming and Generating Method
Gear teeth forming by using an end mill
cutter :
 For cutting teeth of coarse pitch gears or
finishing the teeth of cast gears of coarse
pitch, such as used in rolling mills, etc., end
mill cutters are used.
 Their application avoids the use of costly
disc form cutters.
 They work in the same way as disc form
rotary milling cutters except that their axis
of rotation is situated in a different
direction than that of the latter, with
respect to the axis of the blank.
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 Forming and Generating Method
Gear cutting with single
point form tool.
 Gears can also be cut
by means of single
point form tools on
shaping, planning
and slotting
machines.
 The gear blank is held
on a mandrel
between the centers
of the dividing head
and the tail stock.
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 Forming and Generating Method
Broaching
 It uses a form tool called
broach.
 The broach to be used for this
purpose should carry teeth
which conform in shape to the
profile of the tooth space of the
gear to be cut.
 The main advantage of this
process is that the complete
gear is produced in a single
pass, i.e., the process is very
quick.
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 Gear Generating Process
Gear Shaper Process:
 A pinion shaped cutter is used which
carries clearance on the tooth face and
sides.
 It carries a hole in center for mounting
on a stub arbor or spindle of the m/c.
 The cutter is mounted with its axis
vertical and reciprocated up and down
by sliding the spindle head along the
vertical ways on the machine.

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 Gear Generating Process
Rack planning process:
 It involves the rotation of the gear blank
as the rack type cutter reciprocates in a
vertical direction.
 However, the main problem with this
method is that once the full length of the
rack is utilized the cutting operation has
to be stopped in order to bring the gear
blank back to its starting position.

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 Gear Generating Process
The Sunderland Process:
 In this, the cutter reciprocates in a
direction towards and away from the gear
blank.
 Thus, it is gradually fed into the blank to
the required depth of the tooth as shown
in figure

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 Gear Generating Process
Gear Hobbing Process:
 In this process, the gear blank is
rolled with a rotating cutter
called hob.
 A majority of involute gears are
produced by this method.

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 Gear Finishing Process.
 Gear shaving
 Roll finishing
 Gear grinding
 Gear lapping
 Gear honing

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 Gear Finishing Process.
Gear shaving Process
 It is a process of finishing gear
teeth by running the gear at high
speed in mesh with a gear shaving
tool which is in the form of rack or
pinion.
 The teeth of the shaving tool are
hardened, accurately ground and
their faces are provided with
serrations.

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 Gear Finishing Process.
Roll Finishing:
 It is a cold rolling process, which is
mainly employed for finishing helical
gears.
 It involves the use of two hardened
rolling dies.
 These dies are very accurately
formed to contain the tooth profile of
the gear to be finished.

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 Gear Finishing Process.
Gear grinding:
 The two common methods used for
grinding hardened gear teeth are
forming and generating,
 In forming process the abrasive
wheel is first trued to the required
shape and size of the gear teeth.

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 Gear Finishing Process.
Gear Lapping process
 Those gears which are finish machined or shaved.
 Then heat treated are ultimately lapped to remove scale, improve surface finish
on the teeth
 Rectify small errors due to distortion during hardening process.
 In this process, the gear to be lapped is run under load in mesh with one or more
cast iron toothed laps.
 Gear Finishing Process.
Gear Honing Process:
 Used for finishing gear teeth after shaving and heat treatment.
 Helical gear shaped abrasive tools called hones are used in this process.
 The honing machines used in the process are similar to shaving machines and
operate more or less in the same way.
 Gear Manufacturing
Casting Process :
 Cast iron gears are cast in sand or permanent type of metal moulds.
 These gears are relatively rough, weak and inaccurate, but the cost of production
is very low. This method is therefore, used for large gears only.
 Small cast gears for light duty work are better produced by die casting,
particularly of non-ferrous metals and alloys.
 These gears have sufficient accuracy and high surface finish.
 Gear Manufacturing
Plastic Moulding:
 Plastic molding is used to produce gears of plastic materials for very light work.
 Generally thermo-plastic materials like nylon are used for gear making.
 Injection molding method is commonly used for this purpose.
 If gears are to be molded out of thermosetting plastics, compression moulding
process is used.
 These gears are light weight, highly finished and provide a noiseless drive.
 Gear Manufacturing
Rolling Process:
 Hot rolling process used for making gears also.
 To produce the desired teeth on its periphery hot gear blank is rolled against a
master gear.
 The force between the master gear and the blank makes the metal flow and obtain
the shape and size of the teeth of the master gear.
 The cold rolling process is also advantageously used for producing gear teeth,
especially spur and helical gears.
 Highly finished and smooth surface on their teeth, The gears produced through this
process.
 Gear Manufacturing
Extrusion Process:
 This process is largely limited to the production of small size accurate gears from
soft materials like brass, aluminum, bronze, etc.
 For mass production of such gears a preferable practice is to extrude a bar through
a forming die, such that the entire surface of the bar will carry the gear tooth
shapes all along its length.
 Then, smaller lengths are cut-off from this bar, each small length being equal to the
thickness of the required gear.
 These gears may need subsequent operations like finish machining of teeth,
making a central hole, etc.
 Gear Manufacturing
Stamping Process:
 Used for mass production of small and thin gears out of metal sheets, such as for
small and light gear mechanisms used for toys, watches, measuring gauges,
domestic appliances, etc.
 Gear materials – brass, bronze, aluminium alloys, stainless steel, medium carbon
steel, etc.
 Thicknesses – limited up to 1.5 mm, but for special applications thicknesses up to
12.5 mm have been successfully stamped.
 Gear Manufacturing
Powder Metallurgy :
 Highly accurate and finished, gears up to 25 mm diameter in general can be easily
produced through powder metallurgy process.
 This type of gears are normally used in precision instruments & appliances.
 This process will be economically viable only when the required number of such
gears is quite large.
 Gears made through this process are strong and normally do not need or require
further machining.
References:
 Books:
 Metal Cutting Principles,M C Shaw; MIT Press, 2004.
 Tool Design, Donaldson; Tata McGraw Hill.
 Fundamentals of machining and machine tools Boothroyd; CRC Publication.
 Production Technology HMT.
 P C Sharma, “A Textbook Of Production Engineering”. S. Chand publishers.
 Workshop Technology Raghuvanshi; Dhanpat Rai Pub
 Production Technology,R.K. Jain; Khanna Pub
References:
 Video Links
 https://www.youtube.com/watch?v=vS7v0_lPMdc
 https://www.youtube.com/watch?v=qDqwKAwU-S8
 https://www.youtube.com/watch?v=lIOr-aZ_ZHk&t=1s
 https://www.youtube.com/watch?v=lIOr-aZ_ZHk&t=98s
 https://www.youtube.com/watch?v=wZEG8lmgDoQ
www.paruluniversity.ac.in