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Manufacturing Processes II

THREAD & GEAR


MANUFACTURING

Dr. M. Abu Hayat Mithu


Associate Professor

Department of Industrial & Production Engineering


Shahjalal University of Science & Technology, Sylhet
IPE 317

Lecture Outcomes

Screw Threads

 Identify general applications of various objects having screw threads


 Classify the different types of screw threads
 State possible methods of producing threads and their characteristics.
 Visualise and describe various methods of producing screw threads by:
(a) Machining, (b) Rolling, (c) Grinding, and (d) Other methods

Gear Manufacturing

 State the basic purposes of use and general applications of gears


 Classify various types of gears of common use
 Specify gears
 Describe different methods of manufacturing gears by: (a) Preforming,
(b) Machining, (c) Finishing gear teeth, and (d) Other methods
Dr. M.A.H. Mithu, IPE, SUST 02
IPE 317

Introduction: Threads

Machine parts are held together, adjusted, or moved by screw


threads of many sizes and kinds. Screw threads are
commonly used as fasteners, to transmit power or motion,
and for adjustment. Different thread forms (V, square, acme)
and thread series (coarse, fine, and so on) are available. The
screw threads used in manufacturing should conform to an
established standard to be interchangeable and replaceable.
Threaded fastener
Part A Part B
- bolts and nuts
- studs Part C

- screws
Thread Applications
- To hold parts together (primary job)
- To move part(s) relative to others (secondary job).
Dr. M.A.H. Mithu, IPE, SUST 03
IPE 317

Application of Threads

 Fastening: screws, nut-bolts and studs are used for


temporarily fixing one part on to another part;
 Joining: co-axial joining of rods, tubes etc;
 Clamping: strongly holding e.g., c-clamps, vices, tailstock;
 Controlled linear movement : e.g., travel of slides, work
tables in milling machine, shaping machine, CNC machine;
 Transmission of motion and power : e.g., lead screws of
machine tools
 Converting rotary motion to translation : rotation of the
screw causing linear travel of the nut in machine tools;
 Position control in instruments : e.g., screws enabling
precision movement of the work table in microscopes etc;
 Precision measurement of length : e.g., micrometers;
 Exerting heavy force : e.g., mechanical presses, conveying
and squeezing materials, controlled automatic feeding etc.
Dr. M.A.H. Mithu, IPE, SUST 04
IPE 317

Classification of Threads

Screw threads can be classified as follows:


According to location
 External screw thread (on bolts etc.)
 Internal screw thread (in nuts etc.)
According to configuration
 Straight (helical) – most common, e.g., bolts, studs
 Internal screw thread (in nuts etc.) taper (helical),
e.g., in drill chuck
 Radial (scroll) as in self centering chuck
According to the direction of the helix
 Right hand (common)
 Left hand (occasionally), e.g., gas cylinder etc.
Dr. M.A.H. Mithu, IPE, SUST 05
IPE 317

Classification of Threads cont…

According to form
 Vee thread (600 or 550 angle) – most common
 ACME thread (290)
 Square thread (generally in power screws)
 Buttress thread (45o)
 Worm thread (290 ~ 400)
 Semicircular (groove section) thread being used in
recirculating type bolts, screws.

According to the standard


 BSW (British Standard Whitworth) thread – size is
designated by TPI (threads per inch)
 Metric thread, thread size is specified by pitch or
lead (in mm)
Dr. M.A.H. Mithu, IPE, SUST 06
IPE 317

Classification of Threads cont…

According to the number of start


 Single start – most common
 Multi-start (2 to 4)

According to the spacing of threads


 TPI (no. of threads per inch), e.g. 12 TPI
 Pitch (or lead) – distance between two successive
threads, in mm

According to the compactness or fineness of threads


 General threads (with usually wide thread spacing),
pipe threads (more densed desired)
 Fine threads (generally for leak proof)
Dr. M.A.H. Mithu, IPE, SUST 07
IPE 317

Classification of Threads cont…

According to the segmentation


 Full threads (common)
 Half turns as in half nuts
 Sector thread – e.g., in the jaws of lathe chucks.

The standard and most widely used threads are as follows:


 ISO metric thread
 Unified thread, unified coarse (UNC) & unified fine (UNF)
 Whitworth thread, proposed by Sir J. Whitworth
 British association (BA) thread, dia less than 1/4 in
 Square thread, used for power transmission
 Acme thread, has 29° thread angle
 Trapezoidal metric thread, has a 30° thread angle.
Dr. M.A.H. Mithu, IPE, SUST 08
IPE 317

Classification of Threads cont…

External (male) A thread cut on the outside of External


thread a cylindrical body. thread

Internal
Internal A thread cut on the inside of
thread
(female) thread
a cylindrical body.

Right-hand Thread that assemble when


thread
turned clockwise.

Left-hand Thread that assemble when


thread
turned counter-clockwise.
Turnbuckle use RH and LH thread at each end to double displacement.
Dr. M.A.H. Mithu, IPE, SUST 09
IPE 317

Terms used of a screw thread

Minor dia.

Major dia.
Major The largest diameter on
diameter an internal or external thread.

Minor The smallest diameter on

Major dia.
Minor dia.
diameter an internal or external thread.

External Thread
Crest The bottom of the thread cut into Thread
a cylindrical body. angle

Root The peak edge of a thread.


Root Crest

Thread angle The angle between threads


faces.
Dr. M.A.H. Mithu, IPE, SUST 10
IPE 317

Terms used of a screw thread cont…

pitch

Pitch The distance between two succeeding


crests (or roots) of a screw or thread.

Lead The distance a screw will advance


when turned 360o.

Example :
Knuckle thread form

Dr. M.A.H. Mithu, IPE, SUST 11


IPE 317

Terms used of a screw thread cont…

Pitch diameter
Other Specifications
Diameter of imaginary cylinder
that passes through thread at point
where groove and thread widths
are equal.
TPI
The number of threads per inch.
Thread Types
ISO Metric
American National Standard Thread
British Standard Whitworth Thread
Four main series:
Unified Thread
American National Acme Thread
National Coarse (NC)
National Fine (NF) Square Thread
National Special (NS) Brown & Sharpe Worm Thread
National Pipe (NPT) International Metric thread
Dr. M.A.H. Mithu, IPE, SUST 12
IPE 317

Terms used of a screw thread cont…

ISO Metric Thread


60° included angle
D (Internal) = 0.6143 x pitch
Crest = .125 x pitch
Root = .250 x pitch
P/8
Internal 60o
thread
P/4

External
Pitch, P
thread
CL

Nom. dia (mm) Pitch (mm) Nom. dia (mm) Pitch Nom. dia (mm) Pitch
1.6 0.35 3.5 0.6 24 3.0
2 0.4 4 0.7 30 3.5
2.5 0.45 5 0.8 36 4.0
3 0.5 20 2.5 42 4.5
Dr. M.A.H. Mithu, IPE, SUST 13
IPE 317

Screw Thread Representation

External thread Internal thread


Thread runout
Detailed
representation

Pitch 60o

Schematic
representation
Pitch Root (thick line)
Crest (thin line)

Thread runout
Simplified
Pitch/2
representation

Root
Dr. M.A.H. Mithu, IPE, SUST 14
IPE 317

Possible methods screw thread production

Production of screw thread

Casting Rolling Machining

→ Sand casting
→ Flat dies
→ Die casting
→ Circular dies
→ Permanent mold
Cutting Grinding
→ Plastic molding
→ Traverse
→ Shell molding Single-point tool Multipoint tool
grinding
→ Lost wax → Turning on a → Die heads
lathe → Chasing → Plunge
→ Tapping → Milling grinding
Dr. M.A.H. Mithu, IPE, SUST
→ Broaching 15
IPE 317

Possible methods screw thread production

Among several methods for generating threads on metallic part:

Conventional methods Non-conventional methods


— Manual thread cutting — Thread lapping
(with taps and dies) — Threading with EDM
— Single-point threading — Additive methods
(thread turning) - Fused deposition modeling
— Multi-teeth threading
- Direct metal laser sintering
(thread milling)
- 3D printing,
— Thrilling (drilling &
- Solid freeform fabrication
threading internal threads)
- Layered object
— Thread grinding
— Thread forming and rolling manufacturing, and
— Thread casting and molding - Streolithography.
Dr. M.A.H. Mithu, IPE, SUST 16
IPE 317

Fabrication of Threads

The method chosen for any application is based on:


 time; money; degree of precision needed; or
 what equipment is already available;
 what equipment purchases could be justified;
 how many parts are planned to fabricate; etc.
Manual Main articles: Tap and die and Tap or die handle.
Threading A tap (for internal threads)/ die (for external thread)
cuts threads in predrilled hole or on a pre-shaped
workpiece, remove chip by clockwise rotation.

Machine Main articles: Machine tool & shaped cutting tool.


Threading Tool moves linearly while the precise rotation of the
workpiece, held in a chuck or mounted between two
centers, determines the lead of the thread.
Dr. M.A.H. Mithu, IPE, SUST 17
IPE 317

Fabrication of threads: Manually

External thread Internal thread


Threading die Twist drill

Tap
Die stock
Tap wrench

Dr. M.A.H. Mithu, IPE, SUST 18


IPE 317

Fabrication of threads: Manually

Die Threading: Used to cut external


threads on round work Adjustable screw plate
die
Most common threading dies are:
- Adjustable split die
- Adjustable screw plate die
- Solid die
* Used for chasing or recutting
damaged threads
* May be driven by suitable wrench
* Not adjustable - Two die halves held
Tools in collet by threaded
plate
- Adjusting screws against
each die half
- Greater adjustment
than split die
Die stock
Dr. M.A.H. Mithu, IPE, SUST 19
IPE 317

Fabrication of Threads

Die threading machines


Drill press  Easy to set and simple to operate.
 Threads can be cut manually or by using device.
Manual  Used for small to medium quantities in parts.
turret lathes  When requires other machining operations such
as drilling, turning, reaming, and so on.
Automatic  Include automatic turret lathes, single /multiple
machines spindle automatic bar or chucking type
machine.
 Used for medium- or high-production lots.
Special  WP loading and unloading can be manual,
threading hopper-fed, or fully automatic.
machines  M/cs usually incorporate lead control devices.
 Bar-type machines with collets can handle long
parts to thread rods, shafts, and pipes.
Dr. M.A.H. Mithu, IPE, SUST 20
IPE 317

Fabrication of Threads
Tapping
 Taper :
 Tapered from end six threads
TaperUsed to start tapping

 • Tapered
Used forfrom
tapping
endthrough holes
six threads
 andtoblind
• Used starthole
tapping
 Plug
• Used for tapping through holes and
 blind holefor three threads
Tapered
Plug For Tapping through holes

 Bottoming tap
• Tapered for three threads
 NotTapping
• For tapered but chamfered
through holesat end
 Used fortap
Bottoming threading to bottom of
 blind hole
• Not tapered but chamfered at end 1
Hole•must
Usedbe fordrilled to correct
threading size.of
to bottom Tap drill size: TDS  D -
blind N
hole
Standard, TDS = major diameter (mm) – pitch (mm)
Leaves proper amount of material for tap to cut thread
Dr. M.A.H. Mithu, IPE, SUST 21
IPE 317

Fabrication of Threads: Machining

Internal Threads

Cutting threads in a hole


 - Operation performed on work held in chuck or collet or
 mounted on faceplate
 - Threading tool similar to boring toolbit except shape
 ground to form of thread to be cut
 - Tapping within a machine tool (lathe, milling, drilling etc.)
lath n
ine n a
e
eng tting o
Cu

Dr. M.A.H. Mithu, IPE, SUST 22


IPE 317

Fabrication of Threads: Machining

External Threads
ETs are produced in center lathe by various methods:
 Single point cutting tool of desired angle, and
 Multipoint chasing.
Single point cutting process is slow but can provide high quality.
Multipoint chasing gives more productivity but at the cost of
quality to some extent.

Dr. M.A.H. Mithu, IPE, SUST 23


IPE 317

Fabrication of Threads: Machining

Thread chasing - is the process of cutting a thread on a lathe with


a chasing tool that comprises several single-point tools banked
together in a single tool called a chaser.
 Can also be used for internal threads greater than ϕ25 mm.
 Chaser is moved radially into the WP for each cut.
 Thread chasing reduces the threading time by 50% compared to
single-point threading.

Dr. M.A.H. Mithu, IPE, SUST


Fig. Thread chasers: flat (shank type), block, and circular type 24
IPE 317

Fabrication of Threads: Machining

Thread Milling
This process gives quite fast production by using suitable
thread milling cutters in center lathes (milling machine).
 Milling attachment is mounted on the saddle of the lathe.
Thread milling is of two types:
1. Long thread milling: Long and large
diameter screws e.g., lead screws are
accurately made by using a large disc
type form milling cutter.
2. Short thread milling: Shorter length
and fine pitch are machined at high
production rate. Each job requires
only around 1.25 rev of the blank and
very short axial (1.25 pitch) and
Fig. Long and short thread milling
radial (1.5p) travel of rotating tool.
Dr. M.A.H. Mithu, IPE, SUST 25
IPE 317

Fabrication of Threads: Machining

Thread Milling Machines


Universal Machines have a lead screw and
thread mills cut internal and external threads
(except square threads)

Planetary Machines are used to thread


thread mills odd-shaped parts that are
difficult to be held in a chuck.
WP is held in a special fixture
that does not rotate during
thread cutting.

NC Machines are used for thread


machines milling together with other
operations in a single WP
operation. Long cutter life and
high-quality threads are some of
the advantages of these m/cs.
Dr. M.A.H. Mithu, IPE, SUST 26
IPE 317

Fabrication of Threads: Forming


Thread Rolling
- Most important commercial process for mass producing
external threaded components (e.g., bolts and screws).
- To form threads on cylindrical parts by rolling them between
two dies.
- The dies are of two types: (1) flat dies, and (2) round dies.
- Advantages (i) better material utilization, (ii) stronger threads
due to work hardening, (iii) smoother surface, and (iv) better
fatigue resistance.

Different types of dies and methods are used for thread


rolling which include:
 Thread rolling between two flat dies
 Thread rolling between a pair of circular dies
 Thread rolling by sector dies
Dr. M.A.H. Mithu, IPE, SUST 27
IPE 317

Fabrication of Threads: Forming


 Rolling of external screw threads by flat dies
Flat dies; one fixed and the other moving parallely, are used in
three configurations :
 Horizontal : most convenient and common
 Vertical : occupies less space and facilitates cleaning and
lubrication under gravity
 Inclined : derives benefit of both horizontal and vertical
features
Flat dies are made of hardened cold die steel and provided with
linear parallel threads like grooves of geometry as desired.

Dr. M.A.H. Mithu, IPE, SUST 28


IPE 317

Fabrication of Threads: Forming


 Rolling of external screw threads by flat dies
Circular die sets occupy less space and are simpler in design,
construction, operation and maintenance.

Different types of thread rolling circular dies of common use


and their working methods are:
 Circular dies with plunge
(radial) feed : Two identical
circular dies with parallel axis
are rotated in the same
direction and speed.
One stays fixed in a position
the other is moved radially
desirably depending upon the
thread depth.
Dr. M.A.H. Mithu, IPE, SUST 29
IPE 317

Fabrication of Threads: Forming

 Circular die with inherent


radial feed: Forced penetration
of the threads in the blank is
accomplished not by radial
shifting of one of the dies but
gradual projection of the thread
in Archimedean spiral over an
Circular die with inherent radial feed
angle on one of the dies.
 Thread rolling in the annular
space between two dies: In this
process the outer die remains
fixed and the inner one rotates.
Because of simple construction
and motions, this method is
more productive.
Dr. M.A.H. Mithu, IPE, SUST
Annular space feeding 30
IPE 317

Fabrication of Threads: Forming

 Rolling of screw threads by circular die sectors


The simplest and fastest way of thread rolling enabling
easy auto-feed of the blanks, shown in Fig.

Fine internal threads on large


diameter and unhard metals
may also be done, if needed.

By using a screw like


threaded tool which will be
rotated and pressed parallely
against the inner cylindrical
wall of the product.
Rolling of circular die sectors
Dr. M.A.H. Mithu, IPE, SUST 31
IPE 317

Fabrication of Threads: Forming

Compared to machining thread rolling:


 is generally cold working process,
 provides higher strength to the threads
 does not cause any material loss
 does not require that high accuracy and finish of the blank
 requires simpler machines and tools
 applicable for threads of smaller diameter, shorter length
and finer pitch
 enables much faster production of small products like
screws, bolts, studs etc.
 cannot provide that high accuracy
 is applicable for relatively softer metals
 is used mostly for making external screw threads
 needs separate dies for different threads
Dr. M.A.H. Mithu, IPE, SUST 32
IPE 317

Fabrication of Threads: Other Methods

Thrilling is the process of drilling and threading


g internal threads using a specialized cutting tool on a
CNC mill.
ll in
ri

The cutter first plunges to drill the hole. Second, the


Th

thread is circularly interpolated just like the multiple-


form cutter.
Only a few threads over short length
ti d
as a
ng
C re

Less accuracy and poor finish


Th

Example – threads at the mouth of glass bottles,


spun cast iron pipes etc.
&

Lapping is rarely used process only where thread


g

cutting or grinding in order to achieve the highest


M n
D pi

precision and high surface finish.


E p
La

EDM, Electrical discharge machined (EDM) into hard


materials using a sinker style machine.
Dr. M.A.H. Mithu, IPE, SUST 33
IPE 317

Fabrication of Threads: Grinding

Thread grinding is the preferred method of threading when


the WP hardness is greater than 36 HRC or less than 17 HRC,
and when a high degree of accuracy is required.
Threads are ground in several
methods which include:
 External and internal thread
grinding by single ribbed
formed grinding wheel as
shown in Fig.
 Such grinding is usually
done in cylindrical grinding
m/c but is also occasionally
done in rigid center lathes
by mounting a grinding
attachment. Fig. Single ribbed grinding wheel
Dr. M.A.H. Mithu, IPE, SUST 34
IPE 317

Fabrication of Threads: Grinding

 Multi-ribbed wheels save


grinding time by reducing the
length of travel of the wheel
but raises wheel cost.
 Fig. shows a thread grinding
with both fully covered and
alternate ribbing.
 Two common types:
• Multi rib plunge grinding, and
Fig. Multi-ribbed grinding wheel
• Skip-rib traverse grinding.

Dr. M.A.H. Mithu, IPE, SUST 35


IPE 317

Manufacturing Processes II

GEAR
MANUFACTURING

Dr. M. Abu Hayat Mithu


Associate Professor

Department of Industrial & Production Engineering


Shahjalal University of Science & Technology, Sylhet

Dr. M.A.H. Mithu, IPE, SUST


IPE 317

Introduction to Gear Manufacturing

Gears are machine elements that transmit power and rotary


motion from one shaft to another.
 Gears are basically wheels having, on its periphery,
equispaced teeth which are so designed that those wheels
transmit, without slip, rotary motion smoothly and
uniformly with minimum friction and wear.
 To achieve those favorable conditions, most of the gears
have their tooth form based on involute curve, which can
simply be defined as locus of a point on a straight line
which is rolled on the periphery of a circle.
 Thread cutting and indexing movements in gear cutting
are typical examples, which require synchronized rotary
and linear movements.
Dr. M.A.H. Mithu, IPE, SUST 37
IPE 317

Introduction to Gear Manufacturing

Where used?

Gears are specifically used to:

 Change the speed of rotation,


 Change the direction of rotation (speed direction),
 Increase or reduce the magnitude of speed and torque,
 Convert rotational movement into linear or vice versa
(rack and pinion drive),
 Change angular orientation (bevel gears),
 Offset the location of rotating movement (helical gears
and worm gear sets).
Dr. M.A.H. Mithu, IPE, SUST 02
IPE 317

Introduction to Gear Manufacturing

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 equipments, clocks and watches
 Industrial robots and toys.
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Classification of Gears

Gears are broadly classified as:


According to configuration
 External gear (outside of the periphery)
 Internal gears (inside the periphery)
According to axes of transmission
 Spur gears, transmitting rotation between parallel shafts
o Straight toothed, and
o Helical toothed
⎯ Single helical
⎯ double helical (herringbone)
 Internal screw thread (in nuts etc.) taper (helical),
e.g., in drill chuck
 Radial (scroll) as in self centering chuck
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Classification of Gears cont…

(a) (b)
Fig. Gear configuration: (a) External gears (b) Internal gears

Fig. (a) Straight toothed (b)Helical and (c) Double helical gears
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Classification of Gears cont…

According to axes of transmission


 Bevel gears – transmitting motion between intersecting shafts (axes)

o Straight toothed
o Helical toothed
⎯ Spiral bevel gear
⎯ Hypoid gear
Helical toothed bevel gears are used for smoother and larger
torque transmission.
 Gears transmitting motion and power between two non-
parallel non-intersecting shafts
o Worm and worm wheel
o Spiral gears
o Skewed or hypoid bevel gears

Dr. M.A.H. Mithu, IPE, SUST


IPE 317

Classification of Gears cont…

Worm and worm wheel are generally used for speed


reduction but are irreversible i.e., rotation can be
transmitted only from the worm to the worm wheel unless
the helix angle is tool large.
Spiral gears are used when torque or power to be
transmitted is insignificant.
According to pattern of motion
 Rotation to rotation -wheel type gears
 Rotation to translation or vice versa – e.g. rack and
pinion
o Straight toothed
o Helical toothed
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Classification of Gears cont…

Fig. Bevel gears: (a) straight


toothed,

(b) spiral (c) hypoid


toothed gears

Fig. (a) worm &


worm wheel,

(b) hypoid gear (c) spiral

gears
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Classification of Gears cont…

Fig. Gearing transforming (a) rotation to rotation, (b) rotation to translation

Racks: A rack is a gear of infinite-pitch


circular radius. The teeth may be at
right angles to the edge of the rack and
mesh with a spur gear, or at some other
angle, and engage a helical gear.
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Nomenclature of Gear Elements

Fig. Terms used in gears nomenclature


Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Manufacture of Gears

Manufacture of gears needs several processing operations in


sequential stages depending upon the material and type of
the gears and quality desired. Those stages generally are :
 Preforming the blank without or with teeth
 Annealing of the blank, if required, as in case of forged
or cast steels
 Preparation of the gear blank to the required
dimensions by machining
 Producing teeth or finishing the preformed teeth by
machining
 Full or surface hardening of the machined gear (teeth),
if required
 Finishing teeth, if required, by shaving, grinding etc.
 Inspection of the finished gears.
In this lecture, producing teeth by machining and gear teeth finishing will be discussed.
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Manufacture of Gears

Methods of gear manufacturing

Roughing and semifinishing Finishing

Forming Generating Shaving Grinding Lapping


Manufacture Of Gears
Milling Hobbing

Broaching Rack shaping


Fig. Methods of gear
Shaping Gear shaping cutting and finishing

Bevel template Bevel generation

Dr. M.A.H. Mithu, IPE, SUST


IPE 317

Manufacture of Gears : Preforming

Several techniques are applied for gear blank forming, such as:
 Casting
Gear blanks and even gears along with teeth requiring
substantial to little machining or finishing are produced by
various casting processes. The casting techniques are:
o Sand casting Other methods includes:

o Metal mold casting o Manufacture of gears by rolling


• Powder metallurgy
o Die casting
• Blanking in Press tool
o Investment casting
o Plastic molding
o Shell mold casting
o Extrusion process
o Centrifugal casting
o Wire EDM
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Manufacture of Gears : Machining

Machining is the most common method of fabricating gears.


 Preformed blanks of approximate shape and irregular
surface are machined to desired dimensions.
 Finish and then the teeth are produced generally by
machining and occasionally by rolling.
 Full gears with teeth are made by different processes and
then finished by further machining and / or grinding.
 Accurate gears in finished form are directly produced by
near – net – shape process like rolling, plastic molding,
powder metallurgy etc. requiring slight or no further
finishing.
Most commonly practiced machining methods are :
 Forming– profile of teeth are obtained as replica of form tool.
 Generation–complicated tooth profile are formed by cutting
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Manufacture of Gears : Machining

Shaping, Planing or Slotting


Fig. (a) and (b) show how teeth of
straight toothed spur gear can be
produced in shaping machine.
Both productivity and product
quality are very low, but, for (a) Vertical shaping
making one or few teeth on one
or very few pieces of gears when
required for repairing and
maintenance purpose.
Planing machine is used, if
required at all, for making teeth
of large gears whereas slotting,
generally, for internal gears.
Dr. M.A.H. Mithu, IPE, SUST (b) Horizontal shaping
IPE 317

Manufacture of Gears : Machining

Milling:
In gear milling, to mill one tooth space at a
time, after which the blank is indexed to
the next cutting position. Fig show teeth in
a spur gear cut by peripheral (horizontal)
milling with a disk cutter.
Similarly, end milling can also be used for
cutting teeth in spur or helical gears and is (a) Milling with disk cutter
often used for cutting coarse-pitch teeth in
herringbone gears.
Gear milling is usually confined to:
 One-of-a-kind replacement gears
 Small-lot production
 Roughing and finishing of gears
 Finishing gears with special tooth forms (b) Milling with end
Dr. M.A.H. Mithu, IPE, SUST milling cutter
IPE 317

Manufacture of Gears : Machining

Production of gear teeth by form milling are characterized by :


 use of HSS form milling cutters
 use of ordinary milling machines
 low production rate for
 ⎯ need of indexing after machining each tooth gap
 ⎯ slow speed and feed
 low accuracy and
surface finish
 inventory problem –
due to need of a set
of eight
 End mill type
cutters are used for
teeth of large gears
and / or module. Fig. Herringbone gear cutting
Dr. M.A.H. Mithu, IPE, SUST
IPE 317

Dr. M.A.H. Mithu, IPE, SUST


IPE 317

Dr. M.A.H. Mithu, IPE, SUST


IPE 317

Dr. M.A.H. Mithu, IPE, SUST


IPE 317

Dr. M.A.H. Mithu, IPE, SUST 02

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