MANUFACTURING OF GEARS IN

BEVEL ENGINEERING

PRESENTED BY
Mr. AJIT
Roll No: 14ME-060

Under the Guidance of

Mr. Rohit Munjal
BHARAT GEARS LIMITED,FBD
Department of Mechanical Engineering,
LINGAYA’S VIDYAPEETH
 Content

 Introduction
 Gears & types of gears
 Receiving and inspection department
 Measuring equipments
 Manufacturing process
 Machines
 Application
 Conclusion
 Introduction : About Bharat Gears Ltd

 Bharat Gears Ltd. is one of the leading gear manufacturer in India.

BGL supplies gears to major OEM’s in India and overseas for
different automobile industry like Heavy, Medium & light Trucks,
Utility Vehicles (UV’s), Tractors and Off highway vehicles
 BGL’s strength encompasses world class quality, excellence in
customer responsiveness right from metallurgical quality control of
basic steel to precision of gear cutting, HT and post HT operation
along with state of art machinery. It has diverse product lines with
versatile applications.
 It is a public limited Company. BGL is a major global supplier of
automotive gears and heat treatment furnaces.
 INTRODUCTION TO GEARS

 Gears is a mechanical device used to transmit torque.

 Gears is basically a rotating part having cut teeth, or
cogs, which mesh with another toothed parts.
 It provides the motion positively between parallel,
intersecting or non intersecting non parallel shafts.
TYPES OF GEARS

 . According to the position of axes of the shafts.

 a. Parallel
 1.Spur Gear
 2.Helical Gear
 3.Herringbone Gear
 4.Rack and Pinion
 b. Intersecting
 Bevel Gear
 c. Non-intersecting and Non-parallel
 worm and worm gears
RECEIVING AND INSPECTION

 The administrative function that involves checking of

quality, quantity, and condition of incoming goods
followed by their proper storage.
 Inspection involves the measurement, testing, gauging,
and comparision of materials or items
 MEASURING EQUIPMENTS

 Vernier caliper:-It is a measuring instrument

which can make inside, oitside or depth
measurement
 Micrometer:-It is also known as screw
gauge.It is used to measure inside ,outside or
depth,with the range from 0-300mm.
 Height gauge:-It is used to measure the
height of object by using the underside of
scriber as the datum
 Puppy dial gauge:-It is measure the run out,
height, concentricity and flatness of the
compound.least count of puppy dial gauge is
1 micron.
MANUFACTURING PROCESS

 1.Hobbing
 2.Shaping
 3.Shaving
 4.Grinding
 5.Milling
 6.Chamfering
 7.Deburring
 HOBBING PROCESS

 Hobbing is a machining process for

making gears ,splines, and sprockets
on a hobbing machine.
 Teeth or splines cut into the
workpiece by the cutting tool is
called hob.
 Fast and accurate.
 Relative motion between tool and
work piece obtained by gear train.
 SHAPING PROCESS

 Shaping machine is widely used for

the to make splines, and straight
teeth.
 Blank is mounted on two centers
and tool is reciprocated.
 Indexing mechanism is used to
rotate blank.
 More time is spent due to indexing.
 Teeth are not accurate.
 Preferable for spur gears.
 SHAVING PROCESS

 Gear shaving is a free cutting gear

finishing operation which remove
the small amount of metal from
the surfaces of teeth.
 Its purpose is to correct errors in
index,helix angle, teeth profile,
etc.
 1. Rack type:-In rack type,shaving
tool is kept below gear and
reciprocated
 2.Rotary type:-Grooves are made
on gears shaped cutter
 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.
 MILLING PROCESS

 Disk type form milling cutter is used.

 Gear blank is mounted on mandrel.
 Form cutter is rotated and table is
reciprocated.
 Cutter is moved to radial direction to
provide depth.
 Gear blank is indexed to make another
tooth.
 Gear milling can also be done with end
mill cutter.
 Advantages:
 Economical
 All kind of gears can be cut.
 Preferable for small batch size.
 Roughing and finishing both can be done.

 Disadvantages:
 More milling cutters are reqd.
 More time is spent in indexing.
 Not preferable for mass production.
 Limited for course pitch.
 Variation in shape of tooth.
 These gears are used for slow drive.
 CHAMFERRING

 Process of beveling the extreme sharp end of job.

 To enable free movement of nut on threaded job.
 To remove burrs.
 To make the edge blunt.
 DEBURRING

 A burr is a raised edge or small pieces of material

remaining attached to a work piece after a
modification process.
 It is usually an unwanted piece of material and when
removed with a deburring tool in a process called
deburring
 It may be present in the form of fine wire on the
edges of workpiece.
 OERLIKON MACHINE

 Oerlikon C-29:-In oerlikon

machine,all the operations of
hobbing, shaping, shaving,
deburring, chamfering, drilling ,milling
etc. are operated using this machine
which creates result with precision
following accuracy required.
 Face hobbing:-Here job and tool both
are rotates.
 Face milling:-Here job is fixed and
tool rotates
 BEMCO MACHINE

 Bemco machine is used to remove the

bend in shaft of gears by pressure.
 Bemco machine is used to remove the
errors after the heat treatment process
of gears.
 Applications

 General Applications Of Gears Gears of various type, size and material are widely used
in several machines and systems requiring positive and stepped drive. The major
applications are :
 Speed gear box, feed gear box and some other kinematic units of machine tools
 Speed drives in textile, jute and similar machineries Gear boxes of automobiles
 Speed and / or feed drives of several metal forming machines
 Machineries for mining, tea processing etc.
 Large and heavy duty gear boxes used in cement industries, sugar industries,
cranes, conveyors etc.
 Precision equipment's, clocks and watches
 Industrial robots and toys.
 Conclusion
After completing the industrial training at ‘BHARAT GEARS PVT. LTD.’ I can
say that the industrial training is very important for Engineering students like
me. Practical knowledge is a very important in the every field. It was great
experience during the industrial training and I learnt practically knowledge
about the different machines like Hobbing, Shaping, Shaving etc. uses to cut
the various gear like spur, helical, spline,etc. Various processes such as
turning, milling, grinding, keyway and shaping of gears teaches me a lot of
things. I also took some experience about the organization’s work. The
employees of the company were supportive during the industrial training.
Employees and Ajay sir under whose guidance i took training help me to
understand the mechanisms and theories behind these various processes.
They provide me the proper guidance and information about all the
departments like marketing, production and personnel, etc.
THANK YOU