VISHWAKARMA GOVERNMENT ENGINNERING COLLEGE

Mechanical Engineering
6TH Semester
Production Technology
Gear finishing processes
Enrollment no.:
Gajera Keyur 140170119010
Gajjar Harshit 140170119011
Godhani Maulik 140170119012
Gear Burnishing
BURNISHING PROCESS

 Gear burnishing is a cold working process .

 Burnishing is a polishing and work hardening of a

metallic surface.

 This process will smooth and harden the surface ,

creating a finish which will last longer than one that has
not been burnished.
 During burnishing operation , the burnishing gears are fed
inwards towards the work piece and made to turn a few
rotation in each direction.

 This process can only improve the surface finish of the

teeth and does not correct the tooth profile.
Polishing vs. Burnishing

 Even though polishing occurs as a resultant of burnishing ,

polishing in itself is not burnishing.

 Polishing can only improve surface finish where burnishing

is improve surface finish as well as harden the material.

 Polishing is more about removing material to obtain

desired finish where as burnishing if removing less material
compare to polishing.
Gear Grinding
What is Gear Grinding?

 Process of producing finished gear teeth.

 It is preformed after a gear has been cut and heat treated

to a high hardness.

 Suitable for finishing of hardened gears.

Gear Grinding methods

Three methods:-
1. The profile grinding method
2. Threaded wheel grinding
3. The continuous generating grinding method
The profile grinding method

This method is suitable for small-medium batch

production.

 Grinding is done using a form wheel having shaped to

the exact profile of a gear tooth space like a disk type form
milling cutter.

 Also called form wheel grinding.

 W/P is reciprocated under grinding wheel which is plunge

into the work gear desired shape.
 Teeths are finished one by one and after One tool is
finished to the desired size, blank is indexed to the next
tooth space as in the form milling operations.

 .
Used for spur, helical, bevel & worm gears
Advantages :-

 It has high Geometric accuracy.

Form wheels are able to grind along the whole tooth

profile
Threaded wheel grinding

 Threaded wheel is rotated

about it's own axis and w/p
is also given a rotational
movement in mesh with the
wheel and Periodic feed
back towards the wheel.

 Fast method but more

time required for
Preparation of Wheel.
The continuous generating grinding
method

 Also called generation grinding method.

 A worm ceramic wheel is used.

Either ceramic or CBN wheels with diameters up to

40 mm is used.

 It uses one or two saucer shaped grinding wheels.

Work is mounted on mandrels between centers & it given

rotary as well as reciprocating motion in lateral directions.
 It is only for grinding of an
involute profile.

 It is straight-sided.

Accuracy of gear tooth

depends on accuracy of
wheel.

It is used for spiral, bevel

&hypoid gear.
Advantages:-

 High surface quality.

 Possibility of using the same wheels for different Z.

Disadvantages :-

 Over heating
 Cracking in gear tooth.
Gear Lapping
What is the gear lapping?

 When a gear is manufactured it goes through many

stages, machining and cutting a "blank" to begin with.

 After the gears are cut they are left with machining marks
which cause high spots on the gear surface. These high
spots and irregularities can be a major cause of gear noise.

 Lapping of the gear set is the final process in it's

manufacture and this involves a procedure where the Crown
wheel & Pinion are set up in a gear lapping machine and
run together.
The abrasives remove small amount of metal as the gears
rotate
Advantages of gear lapping:

 Imparting very fine finish to gear teeth.

 Also takes care of surface imperfections.

 Lapping typically improves the wear properties of gear

teeth, and corrects the minute errors in involute profile, helix
angle, tooth spacing and concentricity created in the
forming, cutting or in the heat treatment of the gears.

Images are taken from books & from web.