A SEMINAR REPORT ON

GEAR FINISHING METHODS

PESENTED BY:- KETAN PATEL

GUIDED BY:- YUVRAJ SIR

WHY GEAR FINISHING NECESSERY

None of the methods of gear manufacturing on any

machine produce gears of very accurate dimensions and
shape. Any error crept in the gears during production for
any reason lead to noisy performance of the gear box.
Irregular wear of the teeth and uneven load distribution on
the teeth are the factors enough to cause an early failure of
the gears.so applying methods of finishing after the gear
have been cut on the machine.
 GEAR SHAVING:-
 Gear shaving is a finishing operation that removes small
amounts of metal from the flanks of gear teeth. Gear shaving
may correct small errors in tooth spacing, helix angle, tooth
profile and concentricity.
 Shaving improves to be finish on tooth surfaces and can
eliminate tooth end load concentration, reduce gear noise and
increase load carrying capacity.Shaving has been successfully
used in finishing gears of diametric pitches from 180 to 2.
 Shaving is done by two methods (1) rack shaving (2)rotary
shaving
 RACK SHAVING:-

(i) Rack shaving in which a

rack type shaving tool is
reciprocated under the gear
and in feed takes place at the
end of each stroke. 150 mm
is the maximum diameter of
gear that can be shaved by
the rack method.
FIGURE:-1 RACK SHAVING
 ROTARY SHAVING:-
□ In Rotary shaving, the cutter
has the same basic form as the
rough cut gear. The teeth of the
cutter have grooves cut across
the flanks in planes at right
angles to the axis of the cutter;
these grooves form the cutting
edges, but because only a small
amount of metal­ between 0'03
and 0'08 mm is to be removed.

FIGURE:-2 ROTARY SHAVING

 GEAR BURNISHING
 Burnishing is applied to unhardened gears for
finishing to very accurate dimensions.
 In this method the machined gear is rolled under
pressure with three hardened master gears of high
accuracy and finish.
 Though the method provide smooth and accurate
tooth profile but due to localized residual stress.
 It is very advisable to employ the method on
precision gears.
 GEAR GRINDING:-
 Grinding is a very accurate method and is, though relatively
expensive, more widely used for finishing teeth of different type
and size of gears of hard material or hardened surfaces.
 Hardened gears are difficult to finish by shaving and burnishing
methods.
 Like gear milling, gear grinding is also done on two principles
(i) Forming
(ii)Generation, which is more productive and accurate
 Gear lapping

 The object of employing the lapping process for finishing

gears is to achieve high degree of finish.

 The gear to be finished after machining and heat treatment

and even after grinding is run in mesh with a gear shaped
lapping tool or another mating gear of cast iron.

 Lapping can remove very small amount of metal and correct

small errors up to 0.05mm.
 GEAR HONING:-
 Gear tooth honing is a gear finishing process that improves the surface
finish of the tooth profile and reduces the noise of spur and helical gears
after heat treatment.
 Gear honing is a finishing method for hardened gears The grain size of
the abrasive with which it is charged is selected to suit the honing
allowance (0'025 to 0.05 mm) and the surface finish requirements. The
work gear is meshed with the honing tool in a crossed­ axis relationship.
There is no in feed mechanism. The gear is run in both the directions
during the process.
 Gear tooth honing can be carried out with either a constant
pressure between teeth of the gear and honing tool
 REFERENCES:-
1. A text book of production engineering science
by :- c.k pandey
2. Images by Google on 25/9/2010
3. http://nptel.iitm.ac.in visited on 25-9-2010
THE
END