This document discusses various methods for manufacturing gears. It begins by describing common gear parameters like pitch circle, tooth pitch, and tooth height. It then covers several methods for machining spur gears, including milling using a dividing method or rolling method, imaging with a comb knife, and imaging with a disc knife. Methods for machining bevel gears with straight, bevel, and curved teeth are also examined, such as mapping according to a template, reversal with two knives, and gear milling. Finishing processes like honing and grinding are briefly outlined. The document provides diagrams to illustrate the different gear manufacturing techniques.
The document discusses various methods for manufacturing gears, including:
- Gear shaping and hobbing are generating processes that use rotating cutters to form gear teeth profiles. Gear shaping can produce external and internal spur gears with high accuracy, while hobbing is used for external spur gears and worm wheels.
- Gear milling uses form cutters but requires indexing after each tooth, resulting in lower productivity and accuracy than generating processes.
- Other methods discussed include broaching, rolling, powder metallurgy, casting, and machining smaller gears using EDM or broaching. Finishing processes like grinding, lapping, and burnishing are used to improve gear properties.
Methods of gear manufacturing include casting, hot rolling, stamping, powder metallurgy, extruding, coining, and machining. Machining involves the formed tooth process using milling, broaching, or shaping machines, as well as the template and generating processes. The generating process creates gear teeth through relative motion between the gear blank and cutter, and can be done through planing with an involute rack cutter, hobbing with rotating hob cutters, or shaping using a reciprocating pinion-shaped cutter. Hobbing is well-suited for mass production as it cuts multiple teeth simultaneously through continuous meshing of the hob and gear blank.
Methods of gear manufacturing include casting, hot rolling, stamping, powder metallurgy, extruding, coining, and machining. Machining involves the formed tooth process, template process, and cutter generating process. The formed tooth process machines gears using cutters shaped to the tooth profile and includes milling, broaching, and shaping. The template process guides a cutting tool using a template. The generating process produces gear teeth through relative motion between a gear blank and cutter, as in hobbing and planning. Hobbing is continuous, indexing process that cuts multiple teeth simultaneously.
This document is a research paper about gears manufacturing and production technique, which is one of the most known domain of industrial engineering and production. since gears are used in many applications to transmit motion and movement. So study about them is a must in industrial engineering application.
IRJET - Design and Development of Axial Feed using Recirculating Ball Screw f...IRJET Journal
This document discusses the design and development of an axial feed system using a recirculating ball screw for a 6-axis CNC gear hobbing machine. It begins with an overview of the gear hobbing process and advantages of using a ball screw over a lead screw. It then describes the design process for the axial feed system, which involves selecting a suitable ball screw based on calculations of stroke length, load capacity, rigidity and service life. A 63mm diameter ball screw with 10mm lead is selected that meets the design requirements for axial load, rotational speed and long service life.
The document discusses various methods for generating and finishing gear teeth, including gear shaping with pinion-shaped or rack-shaped cutters, gear hobbing with a helical hob, and broaching. Gear shaping involves rotating a pinion-shaped cutter to cut gear teeth into a gear blank. Gear hobbing uses a helical hob to progressively cut gear teeth as the hob and blank continuously mesh and rotate. Finishing processes like grinding, burnishing, and lapping further improve surface finish and dimensional accuracy.
design and fabrication ofGear cutting attachment in lathe machineabes ec
In Today’s Fast Life Every One Wants To Save Time And Money, Even Small Scale Industrialist Wants To Earn More Profits With Given Limited Resources .Due To The Globalization The Competition Is Increasing Day By Day, Especially Micro Industries Is Facing Lot Of Trouble To Sustain In Throat Cutting Competition. So We Came Up With An Idea Of Saving Money By Desginning And Fabritacting of Attachment of gear cutting in lathe Which Can Save Money Of Small Industrialist By Avoiding The Subcontarction Of Works Which May Required Specail Machines .
The document discusses various methods for manufacturing gears, including:
- Gear shaping and hobbing are generating processes that use rotating cutters to form gear teeth profiles. Gear shaping can produce external and internal spur gears with high accuracy, while hobbing is used for external spur gears and worm wheels.
- Gear milling uses form cutters but requires indexing after each tooth, resulting in lower productivity and accuracy than generating processes.
- Other methods discussed include broaching, rolling, powder metallurgy, casting, and machining smaller gears using EDM or broaching. Finishing processes like grinding, lapping, and burnishing are used to improve gear properties.
Methods of gear manufacturing include casting, hot rolling, stamping, powder metallurgy, extruding, coining, and machining. Machining involves the formed tooth process using milling, broaching, or shaping machines, as well as the template and generating processes. The generating process creates gear teeth through relative motion between the gear blank and cutter, and can be done through planing with an involute rack cutter, hobbing with rotating hob cutters, or shaping using a reciprocating pinion-shaped cutter. Hobbing is well-suited for mass production as it cuts multiple teeth simultaneously through continuous meshing of the hob and gear blank.
Methods of gear manufacturing include casting, hot rolling, stamping, powder metallurgy, extruding, coining, and machining. Machining involves the formed tooth process, template process, and cutter generating process. The formed tooth process machines gears using cutters shaped to the tooth profile and includes milling, broaching, and shaping. The template process guides a cutting tool using a template. The generating process produces gear teeth through relative motion between a gear blank and cutter, as in hobbing and planning. Hobbing is continuous, indexing process that cuts multiple teeth simultaneously.
This document is a research paper about gears manufacturing and production technique, which is one of the most known domain of industrial engineering and production. since gears are used in many applications to transmit motion and movement. So study about them is a must in industrial engineering application.
IRJET - Design and Development of Axial Feed using Recirculating Ball Screw f...IRJET Journal
This document discusses the design and development of an axial feed system using a recirculating ball screw for a 6-axis CNC gear hobbing machine. It begins with an overview of the gear hobbing process and advantages of using a ball screw over a lead screw. It then describes the design process for the axial feed system, which involves selecting a suitable ball screw based on calculations of stroke length, load capacity, rigidity and service life. A 63mm diameter ball screw with 10mm lead is selected that meets the design requirements for axial load, rotational speed and long service life.
The document discusses various methods for generating and finishing gear teeth, including gear shaping with pinion-shaped or rack-shaped cutters, gear hobbing with a helical hob, and broaching. Gear shaping involves rotating a pinion-shaped cutter to cut gear teeth into a gear blank. Gear hobbing uses a helical hob to progressively cut gear teeth as the hob and blank continuously mesh and rotate. Finishing processes like grinding, burnishing, and lapping further improve surface finish and dimensional accuracy.
design and fabrication ofGear cutting attachment in lathe machineabes ec
In Today’s Fast Life Every One Wants To Save Time And Money, Even Small Scale Industrialist Wants To Earn More Profits With Given Limited Resources .Due To The Globalization The Competition Is Increasing Day By Day, Especially Micro Industries Is Facing Lot Of Trouble To Sustain In Throat Cutting Competition. So We Came Up With An Idea Of Saving Money By Desginning And Fabritacting of Attachment of gear cutting in lathe Which Can Save Money Of Small Industrialist By Avoiding The Subcontarction Of Works Which May Required Specail Machines .
Gear manufacturing involves creating gear blanks using processes like casting, forging, or extrusion, then machining them to final dimensions. The starting product for gear machining is called a gear blank. Key properties for gear materials are high tensile strength, endurance strength, low friction, and manufacturability. Common gear machining processes form cutting, form milling, broaching, gear generating, and hobbing use cutting tools to shape the teeth. Finishing operations like grinding or lapping further improve surface finish and accuracy for demanding applications. Design considerations for gears include strength, wear resistance, material selection, alignment, compactness, and lubrication provision.
This document discusses the measurement of gears. It begins by defining gears and describing the main types: spur, helical, bevel, and worm gears. It then discusses various gear terminology such as pitch circle diameter, pressure angle, and module. The document outlines different potential gear errors such as profile error, pitch error, and runout. It describes methods for measuring gear runout, pitch, and profile, including using an eccentricity tester, point-to-point measurement, and optical projection onto a master profile. The focus is on defining key gear features and concepts, and outlining standard techniques for inspecting gears and detecting manufacturing errors.
This document discusses various types of milling machines and their components, as well as milling operations and gear cutting processes. It describes the different classifications of milling machines including column and knee types, vertical milling machines, and bed type milling machines. It also outlines work holding devices, tool holding devices, types of milling cutters, and common milling operations. Finally, it covers gear generation principles, gear cutting processes like gear shaping and hobbing, and finishing processes for gears.
This document discusses various gear manufacturing methods including forming processes like extrusion, stamping, and powder metallurgy as well as machining processes like gear shaping, hobbing, and other gear cutting methods. Extrusion can produce gears of any tooth shape in high volumes but is generally used for smaller non-ferrous gears. Stamping is best for low cost, low precision production while powder metallurgy allows for customizable material properties and reduces machining. Gear shaping and hobbing are true generating processes that cut gear teeth through the motion of cutting tools. Hobbing produces the most accurate gears due to averaging of errors across multiple teeth cuts.
There are several methods for manufacturing gears, including casting, forging, machining, and powder metallurgy. Gears can range in size from small parts in watches to large 9m diameter industrial gears. Gear teeth are primarily made through either form cutting or generation. Form cutting involves machining the gear blank with a cutting tool to produce each tooth profile. Gear generation uses a pinion, rack, or hob shaped cutting tool that meshes with the gear blank to simultaneously cut all teeth.
The presentation gives you information about various manufacturing methods of gears and information about milling machine, milling cutters, & dividing head.
Spur gear presentation,kuet,mechanical,amitav royAmitav Roy
This document outlines the design and construction of a spur gear. It includes the objectives of analytically designing, CAD designing, and constructing a spur gear. It discusses applications of spur gears in increasing or decreasing power and speed. It also covers the selection of cast iron as the gear material. The problem is to design a pair of 20 degree full-depth teeth gears. The solution shows the calculation of pitch, face width, and tooth numbers. Finally, it provides steps for the CAD design and safe construction of the spur gear.
Gears are rotating machine parts that transmit torque via cut teeth that mesh together. There are different types of gears including spur gears, helical gears, worm gears, and rack and pinion gears. Gears are manufactured through various processes like form milling, broaching, gear generating, and gear hobbing. After the initial cutting process, additional finishing operations like shaving, grinding, honing, and lapping may be applied to achieve the required surface finish and dimensional accuracy for the application.
Gears are used to transmit power and motion between shafts. There are several types of gears including spur gears, helical gears, herringbone gears, worm gears, bevel gears, rack and pinion gears, and internal gears. Gears can be produced through forming methods like milling or shaping that use cutters with the same tooth form as the gear. They can also be produced through generating methods like hobbing that use cutters with involute teeth to cut gears of the same module. Forming is less accurate while generating provides higher accuracy and productivity.
5. analysis of spur gear cutting using millingNEERAJKUMAR1898
This document analyzes the process of cutting spur gears using a milling machine. It discusses how spur gears are the simplest type of gear with teeth parallel to the axis. The most common method for cutting spur gears on a milling machine is form cutting, where a cutter with the desired tooth pattern rotates around a stationary gear blank. Key parameters like pressure angle, cutting speed, feed rate, and tooth geometry are analyzed. The document also describes the specific steps for cutting a spur gear using a milling machine, including mounting the gear blank on a dividing head, selecting the proper cutter, and indexing the dividing head to cut each tooth space. Formulas for calculating gear parameters like pitch circle diameter and outside diameter are provided
Gears are important machine elements used for power transmission. There are several types of gears including spur, helical, bevel, rack and pinion, and worm gears. Gears can be manufactured using various processes such as machining, powder metallurgy, stamping, and extrusion. Powder metallurgy involves mixing metal powders, compacting them into gear shapes, sintering to improve strength and density, and optional secondary operations. Form milling is a machining process that uses disc or end mill cutters to cut gear teeth by plunging the rotating cutter into the gear blank.
The document discusses various gear manufacturing processes. It describes gear generating processes like gear milling, hobbing, broaching and shaping. It provides details on gear finishing operations such as grinding, shaving, burnishing, honing and lapping. Various gear types are also covered, including spur gears, helical gears, herringbone gears, rack and pinion gears, worm gears and bevel gears. The document outlines the key steps, advantages and disadvantages of different gear manufacturing and finishing techniques.
This document describes the fabrication process of a spur gear. It begins with introducing gear terminology and classifications of gears. It then presents a design problem to transmit 30hp at 1800rpm, selects cast iron as the material, and calculates the design parameters including pitch, tooth numbers, and face width using strength equations. It describes the milling process for gear fabrication and renders the solidworks design of the gear. The document concludes that the manufactured spur gear from cast iron using milling would meet the strength requirements for the given transmission problem.
A lathe rotates a workpiece about an axis to perform various operations such as cutting, sanding, knurling with tools. It consists of a headstock, bed, carriage, tailstock. The headstock powers the spindle and workpiece. The carriage moves the tool parallel to the axis of rotation. Turret and capstan lathes allow quick tool changes. Automatic lathes can produce identical pieces without operator attention after initial setup.
IRJET- Impact of Ground Water on Forest Productivity in Haliyal Taluka using ...IRJET Journal
This document describes the design, static, and modal analysis of a high-speed motorized milling spindle. It discusses the objectives of optimizing parameters that influence the spindle running at 14,000 rpm with 15 kW power rating. Static deflection analysis is performed to check spindle stiffness. Modal analysis using ANSYS characterizes the spindle's dynamic behavior under different vibration modes to analyze natural frequencies and mode shapes. Three bearing arrangements are considered with varying span lengths and analyzed theoretically and using ANSYS to determine the optimal design.
IRJET- Design, Static, and Modal Analysis of High Speed Motorized Milling Spi...IRJET Journal
This document describes the design, static analysis, and modal analysis of a high-speed motorized milling spindle. It aims to optimize parameters that influence the spindle, which runs at 14,000 rpm with 15 kW power rating. Static deflection analysis is performed to check spindle stiffness. Modal analysis using ANSYS characterizes the spindle's dynamic behavior under different vibration modes to analyze system behavior and obtain natural frequencies and mode shapes. The document discusses the components of the spindle assembly, including the housing, shaft, bearings, and motor materials. It outlines the objectives to design and analyze the spindle using theoretical calculations, FEA, and comparing results to select the optimal design.
The document describes the design and specification of a pair of bevel gears. It outlines a problem to transmit 5 hp at 900 rpm through bevel gears at a 90 degree angle with a pinion diameter of 3.333 inches. It then shows the calculations to determine the key specifications of the gears, such as pitch, face, number of teeth, material, and heat treatment. The calculations are based on factors like torque, velocity, dynamic load, wear load, reliability, and strength. Based on the calculations, steel is selected as the material with a surface compressive strength of 135ksi and heat treatment is also determined.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
The document describes the development of a frugal manufacturing process for white canes used by visually impaired people. Three processes were evaluated: die-necking, split die crimping, and tube spinning. Tube spinning, using a customized roller tool with a radius of 6.5mm and mandrel for support, produced results similar to commercially available canes. Further refinements based on user feedback led to prototype canes with advantages over commercial versions. The aim is to standardize the tube spinning process plan detailing materials, tools, operations, and quality measures.
3 Simple Steps To Buy Verified Payoneer Account In 2024SEOSMMEARTH
Buy Verified Payoneer Account: Quick and Secure Way to Receive Payments
Buy Verified Payoneer Account With 100% secure documents, [ USA, UK, CA ]. Are you looking for a reliable and safe way to receive payments online? Then you need buy verified Payoneer account ! Payoneer is a global payment platform that allows businesses and individuals to send and receive money in over 200 countries.
If You Want To More Information just Contact Now:
Skype: SEOSMMEARTH
Telegram: @seosmmearth
Gmail: seosmmearth@gmail.com
[To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
This PowerPoint compilation offers a comprehensive overview of 20 leading innovation management frameworks and methodologies, selected for their broad applicability across various industries and organizational contexts. These frameworks are valuable resources for a wide range of users, including business professionals, educators, and consultants.
Each framework is presented with visually engaging diagrams and templates, ensuring the content is both informative and appealing. While this compilation is thorough, please note that the slides are intended as supplementary resources and may not be sufficient for standalone instructional purposes.
This compilation is ideal for anyone looking to enhance their understanding of innovation management and drive meaningful change within their organization. Whether you aim to improve product development processes, enhance customer experiences, or drive digital transformation, these frameworks offer valuable insights and tools to help you achieve your goals.
INCLUDED FRAMEWORKS/MODELS:
1. Stanford’s Design Thinking
2. IDEO’s Human-Centered Design
3. Strategyzer’s Business Model Innovation
4. Lean Startup Methodology
5. Agile Innovation Framework
6. Doblin’s Ten Types of Innovation
7. McKinsey’s Three Horizons of Growth
8. Customer Journey Map
9. Christensen’s Disruptive Innovation Theory
10. Blue Ocean Strategy
11. Strategyn’s Jobs-To-Be-Done (JTBD) Framework with Job Map
12. Design Sprint Framework
13. The Double Diamond
14. Lean Six Sigma DMAIC
15. TRIZ Problem-Solving Framework
16. Edward de Bono’s Six Thinking Hats
17. Stage-Gate Model
18. Toyota’s Six Steps of Kaizen
19. Microsoft’s Digital Transformation Framework
20. Design for Six Sigma (DFSS)
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Gear manufacturing involves creating gear blanks using processes like casting, forging, or extrusion, then machining them to final dimensions. The starting product for gear machining is called a gear blank. Key properties for gear materials are high tensile strength, endurance strength, low friction, and manufacturability. Common gear machining processes form cutting, form milling, broaching, gear generating, and hobbing use cutting tools to shape the teeth. Finishing operations like grinding or lapping further improve surface finish and accuracy for demanding applications. Design considerations for gears include strength, wear resistance, material selection, alignment, compactness, and lubrication provision.
This document discusses the measurement of gears. It begins by defining gears and describing the main types: spur, helical, bevel, and worm gears. It then discusses various gear terminology such as pitch circle diameter, pressure angle, and module. The document outlines different potential gear errors such as profile error, pitch error, and runout. It describes methods for measuring gear runout, pitch, and profile, including using an eccentricity tester, point-to-point measurement, and optical projection onto a master profile. The focus is on defining key gear features and concepts, and outlining standard techniques for inspecting gears and detecting manufacturing errors.
This document discusses various types of milling machines and their components, as well as milling operations and gear cutting processes. It describes the different classifications of milling machines including column and knee types, vertical milling machines, and bed type milling machines. It also outlines work holding devices, tool holding devices, types of milling cutters, and common milling operations. Finally, it covers gear generation principles, gear cutting processes like gear shaping and hobbing, and finishing processes for gears.
This document discusses various gear manufacturing methods including forming processes like extrusion, stamping, and powder metallurgy as well as machining processes like gear shaping, hobbing, and other gear cutting methods. Extrusion can produce gears of any tooth shape in high volumes but is generally used for smaller non-ferrous gears. Stamping is best for low cost, low precision production while powder metallurgy allows for customizable material properties and reduces machining. Gear shaping and hobbing are true generating processes that cut gear teeth through the motion of cutting tools. Hobbing produces the most accurate gears due to averaging of errors across multiple teeth cuts.
There are several methods for manufacturing gears, including casting, forging, machining, and powder metallurgy. Gears can range in size from small parts in watches to large 9m diameter industrial gears. Gear teeth are primarily made through either form cutting or generation. Form cutting involves machining the gear blank with a cutting tool to produce each tooth profile. Gear generation uses a pinion, rack, or hob shaped cutting tool that meshes with the gear blank to simultaneously cut all teeth.
The presentation gives you information about various manufacturing methods of gears and information about milling machine, milling cutters, & dividing head.
Spur gear presentation,kuet,mechanical,amitav royAmitav Roy
This document outlines the design and construction of a spur gear. It includes the objectives of analytically designing, CAD designing, and constructing a spur gear. It discusses applications of spur gears in increasing or decreasing power and speed. It also covers the selection of cast iron as the gear material. The problem is to design a pair of 20 degree full-depth teeth gears. The solution shows the calculation of pitch, face width, and tooth numbers. Finally, it provides steps for the CAD design and safe construction of the spur gear.
Gears are rotating machine parts that transmit torque via cut teeth that mesh together. There are different types of gears including spur gears, helical gears, worm gears, and rack and pinion gears. Gears are manufactured through various processes like form milling, broaching, gear generating, and gear hobbing. After the initial cutting process, additional finishing operations like shaving, grinding, honing, and lapping may be applied to achieve the required surface finish and dimensional accuracy for the application.
Gears are used to transmit power and motion between shafts. There are several types of gears including spur gears, helical gears, herringbone gears, worm gears, bevel gears, rack and pinion gears, and internal gears. Gears can be produced through forming methods like milling or shaping that use cutters with the same tooth form as the gear. They can also be produced through generating methods like hobbing that use cutters with involute teeth to cut gears of the same module. Forming is less accurate while generating provides higher accuracy and productivity.
5. analysis of spur gear cutting using millingNEERAJKUMAR1898
This document analyzes the process of cutting spur gears using a milling machine. It discusses how spur gears are the simplest type of gear with teeth parallel to the axis. The most common method for cutting spur gears on a milling machine is form cutting, where a cutter with the desired tooth pattern rotates around a stationary gear blank. Key parameters like pressure angle, cutting speed, feed rate, and tooth geometry are analyzed. The document also describes the specific steps for cutting a spur gear using a milling machine, including mounting the gear blank on a dividing head, selecting the proper cutter, and indexing the dividing head to cut each tooth space. Formulas for calculating gear parameters like pitch circle diameter and outside diameter are provided
Gears are important machine elements used for power transmission. There are several types of gears including spur, helical, bevel, rack and pinion, and worm gears. Gears can be manufactured using various processes such as machining, powder metallurgy, stamping, and extrusion. Powder metallurgy involves mixing metal powders, compacting them into gear shapes, sintering to improve strength and density, and optional secondary operations. Form milling is a machining process that uses disc or end mill cutters to cut gear teeth by plunging the rotating cutter into the gear blank.
The document discusses various gear manufacturing processes. It describes gear generating processes like gear milling, hobbing, broaching and shaping. It provides details on gear finishing operations such as grinding, shaving, burnishing, honing and lapping. Various gear types are also covered, including spur gears, helical gears, herringbone gears, rack and pinion gears, worm gears and bevel gears. The document outlines the key steps, advantages and disadvantages of different gear manufacturing and finishing techniques.
This document describes the fabrication process of a spur gear. It begins with introducing gear terminology and classifications of gears. It then presents a design problem to transmit 30hp at 1800rpm, selects cast iron as the material, and calculates the design parameters including pitch, tooth numbers, and face width using strength equations. It describes the milling process for gear fabrication and renders the solidworks design of the gear. The document concludes that the manufactured spur gear from cast iron using milling would meet the strength requirements for the given transmission problem.
A lathe rotates a workpiece about an axis to perform various operations such as cutting, sanding, knurling with tools. It consists of a headstock, bed, carriage, tailstock. The headstock powers the spindle and workpiece. The carriage moves the tool parallel to the axis of rotation. Turret and capstan lathes allow quick tool changes. Automatic lathes can produce identical pieces without operator attention after initial setup.
IRJET- Impact of Ground Water on Forest Productivity in Haliyal Taluka using ...IRJET Journal
This document describes the design, static, and modal analysis of a high-speed motorized milling spindle. It discusses the objectives of optimizing parameters that influence the spindle running at 14,000 rpm with 15 kW power rating. Static deflection analysis is performed to check spindle stiffness. Modal analysis using ANSYS characterizes the spindle's dynamic behavior under different vibration modes to analyze natural frequencies and mode shapes. Three bearing arrangements are considered with varying span lengths and analyzed theoretically and using ANSYS to determine the optimal design.
IRJET- Design, Static, and Modal Analysis of High Speed Motorized Milling Spi...IRJET Journal
This document describes the design, static analysis, and modal analysis of a high-speed motorized milling spindle. It aims to optimize parameters that influence the spindle, which runs at 14,000 rpm with 15 kW power rating. Static deflection analysis is performed to check spindle stiffness. Modal analysis using ANSYS characterizes the spindle's dynamic behavior under different vibration modes to analyze system behavior and obtain natural frequencies and mode shapes. The document discusses the components of the spindle assembly, including the housing, shaft, bearings, and motor materials. It outlines the objectives to design and analyze the spindle using theoretical calculations, FEA, and comparing results to select the optimal design.
The document describes the design and specification of a pair of bevel gears. It outlines a problem to transmit 5 hp at 900 rpm through bevel gears at a 90 degree angle with a pinion diameter of 3.333 inches. It then shows the calculations to determine the key specifications of the gears, such as pitch, face, number of teeth, material, and heat treatment. The calculations are based on factors like torque, velocity, dynamic load, wear load, reliability, and strength. Based on the calculations, steel is selected as the material with a surface compressive strength of 135ksi and heat treatment is also determined.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
The document describes the development of a frugal manufacturing process for white canes used by visually impaired people. Three processes were evaluated: die-necking, split die crimping, and tube spinning. Tube spinning, using a customized roller tool with a radius of 6.5mm and mandrel for support, produced results similar to commercially available canes. Further refinements based on user feedback led to prototype canes with advantages over commercial versions. The aim is to standardize the tube spinning process plan detailing materials, tools, operations, and quality measures.
3 Simple Steps To Buy Verified Payoneer Account In 2024SEOSMMEARTH
Buy Verified Payoneer Account: Quick and Secure Way to Receive Payments
Buy Verified Payoneer Account With 100% secure documents, [ USA, UK, CA ]. Are you looking for a reliable and safe way to receive payments online? Then you need buy verified Payoneer account ! Payoneer is a global payment platform that allows businesses and individuals to send and receive money in over 200 countries.
If You Want To More Information just Contact Now:
Skype: SEOSMMEARTH
Telegram: @seosmmearth
Gmail: seosmmearth@gmail.com
[To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
This PowerPoint compilation offers a comprehensive overview of 20 leading innovation management frameworks and methodologies, selected for their broad applicability across various industries and organizational contexts. These frameworks are valuable resources for a wide range of users, including business professionals, educators, and consultants.
Each framework is presented with visually engaging diagrams and templates, ensuring the content is both informative and appealing. While this compilation is thorough, please note that the slides are intended as supplementary resources and may not be sufficient for standalone instructional purposes.
This compilation is ideal for anyone looking to enhance their understanding of innovation management and drive meaningful change within their organization. Whether you aim to improve product development processes, enhance customer experiences, or drive digital transformation, these frameworks offer valuable insights and tools to help you achieve your goals.
INCLUDED FRAMEWORKS/MODELS:
1. Stanford’s Design Thinking
2. IDEO’s Human-Centered Design
3. Strategyzer’s Business Model Innovation
4. Lean Startup Methodology
5. Agile Innovation Framework
6. Doblin’s Ten Types of Innovation
7. McKinsey’s Three Horizons of Growth
8. Customer Journey Map
9. Christensen’s Disruptive Innovation Theory
10. Blue Ocean Strategy
11. Strategyn’s Jobs-To-Be-Done (JTBD) Framework with Job Map
12. Design Sprint Framework
13. The Double Diamond
14. Lean Six Sigma DMAIC
15. TRIZ Problem-Solving Framework
16. Edward de Bono’s Six Thinking Hats
17. Stage-Gate Model
18. Toyota’s Six Steps of Kaizen
19. Microsoft’s Digital Transformation Framework
20. Design for Six Sigma (DFSS)
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
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How to Implement a Real Estate CRM SoftwareSalesTown
To implement a CRM for real estate, set clear goals, choose a CRM with key real estate features, and customize it to your needs. Migrate your data, train your team, and use automation to save time. Monitor performance, ensure data security, and use the CRM to enhance marketing. Regularly check its effectiveness to improve your business.
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How are Lilac French Bulldogs Beauty Charming the World and Capturing Hearts....Lacey Max
“After being the most listed dog breed in the United States for 31
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popular canines. The French Bulldog is the new top dog in the
United States as of 2022. The stylish puppy has ascended the
rankings in rapid time despite having health concerns and limited
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HOW TO START UP A COMPANY A STEP-BY-STEP GUIDE.pdf46adnanshahzad
How to Start Up a Company: A Step-by-Step Guide Starting a company is an exciting adventure that combines creativity, strategy, and hard work. It can seem overwhelming at first, but with the right guidance, anyone can transform a great idea into a successful business. Let's dive into how to start up a company, from the initial spark of an idea to securing funding and launching your startup.
Introduction
Have you ever dreamed of turning your innovative idea into a thriving business? Starting a company involves numerous steps and decisions, but don't worry—we're here to help. Whether you're exploring how to start a startup company or wondering how to start up a small business, this guide will walk you through the process, step by step.
How MJ Global Leads the Packaging Industry.pdfMJ Global
MJ Global's success in staying ahead of the curve in the packaging industry is a testament to its dedication to innovation, sustainability, and customer-centricity. By embracing technological advancements, leading in eco-friendly solutions, collaborating with industry leaders, and adapting to evolving consumer preferences, MJ Global continues to set new standards in the packaging sector.
Zodiac Signs and Food Preferences_ What Your Sign Says About Your Tastemy Pandit
Know what your zodiac sign says about your taste in food! Explore how the 12 zodiac signs influence your culinary preferences with insights from MyPandit. Dive into astrology and flavors!
[To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
This presentation is a curated compilation of PowerPoint diagrams and templates designed to illustrate 20 different digital transformation frameworks and models. These frameworks are based on recent industry trends and best practices, ensuring that the content remains relevant and up-to-date.
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1. TECHNICAL UNIVERSITY BRNO
BRNO UNIVERSITY OF TECHNOLOGY
FACULTY OF MECHANICAL ENGINEERING
INSTITUTE OF MECHANICAL TECHNOLOGY
FACULTY OF MECHANICAL ENGINEERING INSTITUTE
OF MANUFACTURING TECHNOLOGY
METHODS OF MANUFACTURING GEARS
Method of the production of part with tooth system
BACHELOR THESIS
BACHELOR THESIS
AUTHOR OF THE WORK DALIBOR KUBLA
AUTHOR
WORK MANAGER Ing. MILAN KALIVODA
SUPERVISOR
Brno 2010
Translated from Czech to English - www.onlinedoctranslator.com
2.
3.
4. FSI BUT BACHELOR THESIS Sheet 4
ABSTRACT
The aim of the bachelor's thesis is to clarify the methods of manufacturing
gears, machines and tools. The practical part compares the production methods for
the selected gears; the rolling method of milling and the splitting method of milling.
Keywords
gears,
way, machining, workpiece, cutting movement.
milling rolling way, milling I divide
ABSTRACT
The purpose of this bachelor thesis is to clarify the methods of production
of gear, machinery and tools. The practical part compares the methods for the
production of gears; method of hobbing milling and method of separating
milling.
Key words
Gear, hobbing milling, separating milling, machining, workpiece, cutting
movement.
BIBLIOGRAPHICAL CITATION
KUBLA, D.Gear manufacturing methods. Brno: University of Technology in Brno,
Faculty of Mechanical Engineering, 2010. p. 41, appendices 8. Supervisor Ing. Milan
Kalivoda.
5. FSI BUT BACHELOR THESIS Sheet 5
Declaration
I declare that I am a bachelor's thesis on the topicGear manufacturing methods
developed independently with the use of professional literature and sources, listed in the
list that forms an appendix to this work.
28/05/2010 ……………………………….
Bachelor's name and surname
6. FSI BUT BACHELOR THESIS Sheet 6
Thanks
I thank the supervisor of my bachelor's thesis, Ing. Milan Kalivod, for his professional
guidance during the creation of the work and for valuable comments and advice. And I would
also like to thank my parents, my brother and, last but not least, my grandfather, who
supported me and helped me during my studies.
7. FSI BUT BACHELOR THESIS Sheet 7
CONTENT
Abstract
Declaration
Thanks
Content
Introduction
1. MANUFACTURE OF GEAR WHEELS
1.1 Machining of front wheel teeth
1.1.1 Basic concepts and gear relationships
1.1.2 Milling by splitting method
1.1.3 Rolling milling
1.1.4 Reversing with a comb knife
1.1.5 Turning with a disc knife
1.1.6 Stretching
1.2 Machining of bevel wheels with straight and bevel teeth
1.2.1 Imaging gearing
1.2.2 Gear milling
1.2.3 Gear stretching
1.3 Machining of bevel gear teeth with curved teeth
1.3.1 Gleason method
1.3.2 The Oerlikon method
1.3.3 The Klingenber method
1.4 Production of screws and screw wheels
1.5 Gear Finishing
1.5.1 Sheving
1.5.2 Honing
1.5.3 Grinding
1.5.4 Lapping
1.5.5 The achieved quantity Randand accuracy
2. MACHINES FOR MANUFACTURING GEARS
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29
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35
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39
40
41
3. COMPARISON OF METHODS ON SELECTED GEAR MANUFACTURERS
3.1 Calculation of a real gear
3.2 Calculation of an imaginary wheel with fewer teeth
3.3 Calculation of an imaginary wheel with more teeth
3.4 Graphical evaluation
Conclusion
List of used sources List of used
abbreviations and symbols List of
attachments
8. FSI BUT BACHELOR THESIS Sheet 8
INTRODUCTION
Formulation of the problem
The production of gears clearly belongs to one of the most interesting
machining processes in the engineering industry as such.
The gears themselves are the basic element by which the transmission and
transformation of mechanical energy and movement is realized in machines. Gear wheels are
among the most complex machine components, both in terms of theory and construction, as
well as production.
Rapid development in the field of design, calculation and production of spur
gears with involute gearing took place in the context of the development of modern
technologies. It is about the constant expansion and improvement of computer
technology, which offered the use of perfect programs for optimized designs of gear
geometry. Furthermore, the development and expansion of numerically controlled
machine tools (CNC), which led not only to greater productivity and more accurate
production, but above all enabled the production of gears with various non-standard
tooth shapes.
The aim of the bachelor thesis
The aim of the bachelor's thesis is to clarify the methods of gear production, machines
and tools needed for the given type of production. The practical part of the bachelor's thesis is
a comparison of two methods of gear production on selected gear products.
Giant. 1 Demonstration of the working area of the machine during gear machining8
9. FSI BUT BACHELOR THESIS Sheet 9
1 MANUFACTURE OF GEARS
Gear machining is one of the most demanding processes in engineering
production. This process requires powerful, precise machines and tools, highly
qualified workers and technicians. When machining gears, it is important to
maintain high precision, durability, efficiency and also noiselessness, as gears are
part of the movement mechanisms of most machines, means of transport and
equipment.
Gear wheels are produced in many variants according to the way the teeth are designed:
- machining front wheel gears,
- machining bevel gear teeth with straight and bevel teeth,
- machining bevel gear teeth with curved teeth.
When it comes to the production of precise gearing, the use of finishing
methods is necessary. These methods are detailed in subsection 1.5.
1.1 Machining of front wheel teeth
Spur gears are machined in different ways depending on the availability of
technology, especially machines, and the required accuracy - see table 1
Tab.1.1 Achieved accuracy of gear teeth for given machining methods
10. FSI BUT BACHELOR THESIS Sheet 10
1.1.1 Basic concepts and gear relationships
The following relationships are necessary for the production and construction of gears:
- pitch circle
d = m.of
wherem is the modulus of aof is the number of teeth
Spur gear modules are standardized according to ČSN 01 4608.
- tooth pitch
(1.1)
p = π.m (1.2)
- tooth height
h = 2.25.m (1.3)
- head circle
dand= d + 2.m (1.4)
- heel ring
dF= d – 2.5.m
Tooth widthb is chosen according to the calculation of the gear strength according to ČSN 01 4686.
(1.5)
Giant. 1.1 Basic gear values
The side profile of the tooth is most often formed by an involute curve. This
curve is created by rolling a straight line along a fixed base circle.
11. FSI BUT BACHELOR THESIS Sheet 11
Giant. 1.2 Formation of an involute curve
It is also possible to produce tooth profiles other than involute ones. They are, for
example, cycloid gears. A cycloid is created as a curve described by the point of the circle (the
so-called forming point) when it is rolled along a straight line. The external cycloid gearing has
an epicycloid outline. Epicycloid (epi-has the meaning above, on the surface) is a curve
described by a point forming a circle when it is rolled outwards along another, basic circle.
When rolling the forming circle along the base circle from the inside describes the point
forming the hypocycloid circle (hypo -has the meaning under, lower).
Giant. 1.3 Formation of a cycloidal curve Giant. 1.4 Formation of epicycloid and hypocycloid
1.1.2 Milling by splitting method
Milling of the teeth in a dividing manner is carried out with cutters
whose profile corresponds to the shape of the tooth gap. Disc or pin cutters
are used.
Giant. 1.5 The principle of machining with a disc shaped cutter
12. FSI BUT BACHELOR THESIS Sheet 12
Giant. 1.6 Disc cutter for
involute gearing
Giant. 1.7 Pin cutter for involute
gearing
During milling, after machining one tooth gap with a dividing device, the workpiece
is rotated by one pitch and another tooth gap is milled. Disc module cutters are produced
for modules m = 0.2 to 16 mm. For roughing the gearing of larger modules (m > 20 mm)
roughing disk cutters with a graduated profile are used. Pin milling cutters for roughing
with module m > 30 mm have a trapezoidal profile and blades in a helix, which enables
the use of larger feeds. When milling oblique teeth with a disk module milling cutter, the
working table of the machine with the workpiece is rotated relative to the axis of the
spindle by the tooth inclination angle βto. Slanted teeth are created by a combination of
the longitudinal movement of the table and the rotational movement of the workpiece.
Milling bevel gear with a pin cutter is the same, but the work table does not rotate.
1.1.3 Rolling milling
This method of manufacturing gearing is more widespread due to its
high work productivity and good gearing accuracy. The tool is a rolling mill
that has the shape of an involute worm and whose profile in the normal plane
is formed by a basic ridge. Spur gears and worm gears can be produced by
rolling milling.
and)Milling straight teeth
Giant. 1.8 Principle of the milling method
straight teeth by rolling
Giant. 1.9 Demonstration of gear milling
roll away3
13. FSI BUT BACHELOR THESIS Sheet 13
The main cutting movement is carried out by a milling cutter that rotates around its axis.
The workpiece is moved to the milling cutter so that its rolling ring rolls along the rolling line of the
milling cutter ridge during its rotation. With each revolution of the workpiece, the milling cutter
makes as many revolutions as the milled wheel has teeth. The cutter axis must be inclined relative
to the workpiece by an angle β, which is the same as the pitch angle of the helix on the pitch
cylinder. We determine the inclination of the cutter according to the right or left inclination of the
teeth.
Giant. 1.10 Position of the tool when milling direct gears
Many older milling machines will machine the workpieceinconsistentway. The new
rolling mills are already modified forconsecutivemilling, where the cutter is in the initial
position under the workpiece and has a feed direction from bottom to top. This method of
machining enables an increase in cutting speed and feed rate.
Giant. 1.11 Consecutive milling of gears and radial approach to depth
b)Milling of oblique teeth
The method of milling oblique teeth is almost the same as milling straight teeth,
with the difference in the setting of the hobbing cutter relative to the workpiece. For
teeth that have a right inclination, it is recommended to use a cutter with a right helix,
and for teeth with a left inclination, a cutter with a left helix, where the axis of the cutter
bends to an angle β - λ. This leads to better milling and eliminates the possibility of tool
jamming.
14. FSI BUT BACHELOR THESIS Sheet 14
Giant. 1.12 Milling of oblique gearing with a left inclination with a left-hand milling cutter
and with a right bevel right-hand cutter
In the case when the right-hand pitch of the gearing is machined with the left-hand helix and vice
versa, then it is necessary to set the axis of the cutter to the angle β + λ.
Giant. 1.13 Milling of bevel gears with a left inclination with a right-hand cutter
and with a right-handed left-handed cutter
1.1.4 Imaging with a comb knife
This method works on the principle of engagement of the tool with the workpiece.
The tool for turning the teeth of front gears with a comb knife is a toothed comb that has
a trapezoidal profile. The cutting motion is performed by the tool and is reciprocating.
The tool is set to the depth of the tooth and machining is done by cutting into the
workpiece. After machining a few tooth gaps, the feed and rotation stops, then the
workpiece moves back to the starting position. The number of tooth gaps produced is
determined by the length of the tool.
The mentioned method of machining gears is also calledthe way of Maag.
15. FSI BUT BACHELOR THESIS Sheet 15
Giant. 1.14 Reversing with a comb knife
1.1.5 Imaging with a disc knife
Turning with a disc knife works on the principle of engagement of two
gears without backlash. The tool and the workpiece roll off each other as if two
spur gears mesh together. It is possible to produce wheels with external as well
as internal gearing. With this method, it is possible to produce several bikes at
once. The bevel gear is turned in the same way, which is then rotated during the
working thread at the angle of inclination of the teeth by means of screw guides.
Turning with a disc knife is also known by the namethe Fellows way.
Giant. 1.15 Turning with a disc knife
16. FSI BUT BACHELOR THESIS Sheet 16
1.1.6 Stretching
Stretching is used in large-scale and mass production, as the costs of producing
the tool are high. Machining is carried out with a set of graduated knives folded into
a block of a drawing mandrel - a tool. The gradation of the knives is done depending
on the type of material of the wheel, the thickness of the chips removed and the
cutting speed. Stretching gears is an economical process, as the removed layer of
material is divided into a large number of edges, i.e. that the durability and service
life of the tool are relatively long.
Giant. 1.16 Gear stretching
1.2 Machining of bevel gear teeth with straight and bevel
teeth
Machining of bevel gears is one of the most demanding methods of
engineering production. Bevel gears have straight, bevel and curved teeth. Bevel
gear teeth are machined by turning, milling and stretching.
The flanks of the teeth are made either by copying, rolling, or shape cutters.
The rolling method is one of the most accurate and is carried out using a dividing
method or continuous rolling.
1.2.1 Representation of gearing
and)Rendering according to the template
A pulley moves along the template, the shape of which corresponds to the shape of the side
of the tooth, which controls the mechanism with the turning knives. The knives are fixed on the
pulley slides. It turns with two knives and thanks to this, both flanks of the tooth are machined at
the same time. In this way, a high quality surface is achieved, as it is machined only with the tips of
the knives. The shape of the template depends on the shape of the tooth, and one template is
enough for the same number of teeth of bevel wheels with different modules.
17. FSI BUT BACHELOR THESIS Sheet 17
Giant. 1.17 Mapping of bevel gear teeth by copying
b)Reversal with two knives
In the machine, two trapezoidal knives are clamped in the knife holders of the rotating knife
head. The knives make a cutting movement in the direction of the surface lines of the flanks of the
teeth and at the same time rotate with the knife head around its axis. The bevel wheel is clamped
in the headstock, which is set in a position corresponding to the apex angle of the machined wheel.
The edges of the knives are formed by the flanks of the teeth in the shape of an involute when the
knife head and the working wheel are rotated simultaneously. At the same time, the right side of
the tooth is machined with one knife and the left side with the other knife. After that, both the knife
head and the workpiece return to the initial position, and the workpiece is rotated by one pitch with
the dividing device.
Giant. 1.18 Reversal of bevel gear teeth with two knives1
18. FSI BUT BACHELOR THESIS Sheet 18
1.2.2 Gear milling
Straight and bevel gears are milled with form cutters using a dividing
method, or with two disk knife heads.
and)Milling with shaped cutters
Milling with shaped cutters is used for the production of bevel wheels that do not
require great precision and also for the production of wheels of large modules and
diameters. The tool is a shaped disc or pin cutter. The tooth gap is machined gradually,
first the center is roughened, then the wheel is turned and one side of the tooth is milled,
and the same is repeated for the other side of the tooth.
Giant. 1.19 Milling of bevel gear teeth with a shaped disk cutter
b)Milling with two disc knife heads
The tool consists of two disc heads with mutual edges that overlap in the
tooth gap. The workpiece performs a radial feed to the depth of the tooth.
The gearing is milled using a rolling method.
19. FSI BUT BACHELOR THESIS Sheet 19
Giant. 1.20 Milling bevel gear teeth with two disc knives
heads
1.2.3 Gear stretching
The production of bevel wheels in mass and serial production is most
productive by drawing with a large-diameter (up to 600 mm) disk draw, which has
graduated edges with the shape of a tooth gap on its circumference. The tool
performs a rotational movement and moves along the tooth from a smaller profile to
a larger one. Stretching one tooth gap takes approximately 4 to 6 seconds, so this
process is fast and productive.
Giant. 1.21 Stretching of bevel gears1
20. FSI BUT BACHELOR THESIS Sheet 20
1.3 Machining of bevel gears with curved teeth
Machining of curved teeth of bevel gears is carried out by roller milling
in the following ways:
- Gleason – the teeth are circular spiral,
- Oerlikon – teeth curved according to the cycloid,
- Klingenber – the teeth are curved according to the involute.
1.3.1 Gleason method
This production method is characterized as milling bevel wheels by dividing the
front knife head. The principle consists in the engagement of the machined wheel
and the base wheel. The front knife head rotates independently of other movements
of the mechanism. The cutting movement is created by the rotary movement of the
workpiece and the rotation of the drive plate with the knife head. The workpiece is
moved to the depth of the tooth gap and the tooth gap is milled again. After that, the
workpiece is moved away, the knife head is moved to the initial position, and thus
the division into the next tooth takes place, and the process repeats.
Giant. 1.22 The Gleason method1
1.3.2 The Oerlikon method
Gearing is produced by three movements:
1. rotary movement of the knife head
2. turning the workpiece
3. by turning the cradle – here the clamped front knife head is located
The blades with a straight edge are arranged in such a way that parts of separate
spirals are formed.
21. FSI BUT BACHELOR THESIS Sheet 21
Giant. 1.23 The Oerlikon method1
1.3.3 The Klingenberg method
Gearing is produced by three movements:
1. rotary motion
2. turning the workpiece
3. rolling of the cutter on the drifting board
This method is used for piece and small batch production.
Giant. 1.24 The Klingenberg method1
22. FSI BUT BACHELOR THESIS Sheet 22
1.4 Production of screws and screw wheels
The production of augers is carried out either by turning with the help of a shaping knife,
similar to the production of threads, or by a disc milling machine in a rolling method on universal
milling machines.
Giant. 1.25 Example of screw milling3
Worm gears are usually produced with a hobbing mill that has a worm profile. The axis of the
cutter is perpendicular to the axis of the machined wheel and lies exactly in half the thickness of the
wheel.
Giant. 1.26 Worm gears
23. FSI BUT BACHELOR THESIS Sheet 23
Worm gears can transmit large powers, usually 50 to 100 kW. Another
advantage is small dimensions and thus also lower weight. Worm gears have
high transmission ratios i = 5 to 100, they are self-locking, i.e. there is no
spinning. They are characterized by calm and quiet operation.
The disadvantage is relatively large frictional forces during transmission, worm wheels are
made of different materials. The production of gearing is more demanding, more expensive, and
its service life is usually lower than that of rolling gears due to wear.
1.5 Gear Finishing
Precision wheels classified in the 1st to 4th degree of accuracy. Heat-
treated wheels are finished by shaving, grinding and lapping.
1.5.1 Sheving
This method of gear finishing is used for unhardened wheels, or after
cementing before hardening, produced by roll milling or turning. The shaving tool is
a corrected gear wheel with straight or slanted teeth, which have grooves on the
sides, and these grooves form edges and a space for the removal of chips. The
finishing allowance for hemming is very small, 0.1 to 0.15 mm. The axes of the tool
and the workpiece are crossed at an angle of 5 to 15°. The tool moves along the
entire width of the tooth. The finishing wheel makes a reciprocating sliding
movement in the direction of its axis. In chamfering, the direction of rotation of both
the tool and the workpiece changes at the extreme dead ends.
Giant. 1.27 Sheving of spur gears
24. FSI BUT BACHELOR THESIS Sheet 24
Giant. 1.28 The shape of the tooth of the shaving wheel
1.5.2 Honing
It is a very similar method of hemming. The difference is that the shaving wheel
is replaced by a wheel made of a mixture of plastic and abrasive. Honing is used to
improve the geometric properties and surface roughness of hardened gears.
1.5.3 Grinding
Grinding removes inaccuracies after machining and deformations after
heat treatment of gears. Grinding of gears is carried out by a dividing method
with shaped discs, a dividing method with rolling of the side of the tooth, and
a rolling method.
and)Grinding in a dividing way with shaped discs
In the splitting method, the sides of the teeth are ground with a one-sided or
double-sided shaped grinding wheel. The shape of the profile of the grinding wheel
corresponds to the shape of the side of the tooth. Either grinding with one or two
discs is used. When grinding with two tools, each tool grinds one side of the tooth.
Split grinding is less accurate and its other disadvantage is the difficulty of matching
the grinding wheels to the exact shape.
Giant. 1.29 Shape grinding of teeth
disc
Giant. 1.30 Grinding with two shapes
discs
25. FSI BUT BACHELOR THESIS Sheet 25
b)Grinding in a dividing way with a roll-off of the side of the tooth
Depending on the arrangement of the grinders, this method is
implemented for the case when the ground tooth rolls along one or two grinding
wheels. Grinding in this way has negative effects.
Giant. 1.31 Grinding in a splitting method with rolling of the side of the
tooth a) with one grinding wheel
b) two disc grinding wheels
C)Rolling grinding
Rolling grinding is more accurate than splitting grinding. A ground gear
performs a rolling motion along an imaginary toothed rack. Part of that ridge
can be formed by a trapezoidal grinding wheel or two disc wheels. The most
efficient method is grinding with a disc in the shape of an involute worm,
which works on the same principle as in the rolling method of milling.
Giant. 1.32 Rolling method of grinding with an involute-shaped grinding wheel
snail
1.5.4 Lapping
Lapping removes the last surface irregularities on the sides of the teeth.
Lapping is often used to finish bevel gears with curved teeth that cannot be
ground. The lapped wheel is engaged with a cast-iron wheel of the same
module. Lapping paste or a mixture of oil and abrasive is added to the wheel
engagement. Lapping allowances are around 0.02 to 0.05 mm.
26. FSI BUT BACHELOR THESIS Sheet 26
1.5.5 The achieved quantity Randand accuracy
Since great demands are placed on gears, we distinguish 8 degrees of accuracy. In order to
achieve a certain degree of accuracy, it is necessary to choose a certain type of production, but at
the same time it is necessary to observe the average arithmetic deviation of the profile of the side
of the teeth.
Tab. 1.2 Achieved hardness and R valuesandduring production
IT Way
production
Greatness
Rand[µm]
Grinding on the most precise roller grinders
1. and lapping
2. Grinding on the most precise roller grinders
0.1 to 0.2
0.2
Grinding on very precise roller grinders,
3. milling on special rolling mills designed for milling
precision wheels
Grinding on precision roller grinders,
4. milling on special rolling milling machines
Grinding on precise rolling and profile machines
5. grinders, turning, shaving, milling on precision
milling machines
Milling and turning on regular, carefully
6. Adjusted machines, non-hardened wheels
On ordinary machines in the rolling method. For
7. machining teeth can be heat treated
8. By milling or turning with shape machines
0.2 to 0.4
0.2 to 0.4
0.2 to 0.8
0.8 to 1.6
1.6 to 6.3
6.3 to 12.5
2 GEAR MANUFACTURING MACHINES
Machines on which the production of gears is carried out:
a) cutters for front gears, rolling method,
b) cutters for bevel gears, dividing and rolling method,
c) milling machines for face, screw and worm wheels, rolling method,
d) milling machines for bevel wheels with spiral gearing, dividing and rolling
method,
e) machines for spur and bevel wheels with straight teeth, various methods,
f) universal milling machines for face and bevel wheels, working with a shank milling cutter -
dividing,
g) gear grinders,
h) special gearing machines.
Machines for the production of gears are universal or with CNC control. Universal
machines are still often used nowadays, but from the point of view of the possibilities of
designing the shape of the teeth, machines with CNC control, which can work in a multi-
axis system, are preferred. Examples of some types of CNC machines see appendix 6,7
and 8.
27. FSI BUT BACHELOR THESIS Sheet 27
and)Turning tools for front gears, rolling method
- vertical, working with a comb knife (Maag), one slide:
- ∅wheels up to 500 mm,
- ∅wheels over 1000 to 2000 mm,
- ∅wheels over 2000 mm.
- vertical, working with a comb knife (Maag), two sliders (e.g. Maag
shapers type DSH 20)
- vertical, working with a wheel knife (Fellows):
- ∅wheels up to 315 mm,
- ∅wheels over 315 to 630 mm,
- ∅wheels over 630 mm.
- horizontal on straight teeth, working with one knife
b)Bevel gear cutters, dividing and rolling method
- rolling method, straight and inclined teeth:
- ∅wheels up to 315 mm,
- ∅wheels over 315 mm to 630 mm,
- ∅wheels over 630 mm.
C)Milling machines for face, screw and worm wheels, rolling method
- without differential (only straight teeth)∅wheels up to 400 mm
- with differential (straight screw and worm teeth):
- ∅wheels over 160 to 400 mm,
- ∅wheels over 400 to 1000 mm,
- ∅wheels over 1000 to 2500 mm,
- ∅wheels over 2500 mm.
d)Milling machines for bevel wheels with spiral gearing, dividing and rolling
method
- rolling method special, for roughing the pinion
- rolling method special, for finishing the pinion
- special dividing method, for roughing disc wheels
- dividing method special, for finishing disc wheels
- rolling method of all constructions (Gleason, Klingenberg, Spiromatic,
FM):
- ∅wheels up to 160 mm,
- ∅wheels over 160 to 250 mm,
- ∅wheels over 250 to 400 mm,
- ∅wheels over 400 to 630 mm,
- ∅wheels over 630 mm.
E)Machines for spur and bevel gears with straight teeth, different style
28. FSI BUT BACHELOR THESIS Sheet 28
F)Universal milling machines for face and bevel wheels, working with a shank cutter - dividing
G)Gear grinders
- working with rolling arc, straight and helical teeth:
- ∅wheels over 315 to 630 mm,
- ∅wheels over 630 mm.
- without rolling arc, straight and helical teeth:
- ∅wheels up to 400 mm,
- ∅wheels over 400 to 800 mm,
- ∅wheels over 800 mm.
- grinders for internal gears
h)Special gearing machines
- milling machines for rounding teeth
- milling machines for chamfering the edges of teeth
- lapping and running-in machines for front wheels
- lapping and running-in machines for bevel wheels
- shaving machines:
- ∅wheels up to 315 mm (e.g. USSR machine type "571"),
- ∅wheels over 315 mm (e.g. USSR machine type "5715").
Specific types of machines:
Milling machines–FO 6, FO 8, FO 10, OFA 16A, OFA 71, 5B 312, 5K 324 A, 53 A 20,
RA 300, CNC Höffler HF900
Pictures–OH 6, OHA 16B, OHA 50, OHA 50A, OHO 20, OHO 50, DSH 20,
MAAG SH 75, FELLOWS 10-5 CNC, K4a, S526
Note : Illustrations of some types of machines in Annexes 2, 3, 4 and 5.
29. FSI BUT BACHELOR THESIS Sheet 29
3 COMPARISON OF METHODS AT SELECTED DENTAL
MANUFACTURERS
The practical part of the bachelor's thesis is a comparison of methods for the
production of spur gears. This is a method of rolling milling and milling with a dividing
method.
The comparison will take place in such a way that the machine production times of a
real gear wheel and two imaginary wheels that differ in the number of teeth are determined.
This is how the machine times will be determined for both selected methods of gear
production. There will be the same tools for all three wheels, i.e. a hobbing cutter and a disc
cutter. Milling of the wheel will be done on a rolling milling machine FO 10.
The actual gear comes from COK Farm, where it was part of the scraper
drum of an American New Holland NH 648 round baler and due to heavy
wear had to be taken out of service and replaced with a new gear.
Giant. 3.1 A real gear with straight teeth
Wheel parameters:
- material 14220 (manganese chrome steel for cementing and refining with large
core strength)
- 24 teeth
- module 8
- engagement angle of the side of the teeth 20°
30. FSI BUT BACHELOR THESIS Sheet 30
3.1 Calculation of a real gear
Calculation of wheel dimensions:
Giant. 3.2 Basic dimensions of the gear wheel
Tooth pitch
= ∙
= ∙ 8 = 28.133
(3.1)
Basic spacing
= ∙
= 28.133 ∙ 20° = 23.617
(3.2)
Pitch circle diameter
= ∙
= 8 ∙ 24 = 192
(3.3)
The diameter of the base circle
= ∙ ∙
= 8 ∙ 24 ∙ 20° = 180.421
(3.4)
Diameter of head circumference
= + 2 ∙
= 192 + 2 ∙ 8 = 208
(3.5)
Head clearance
= 0.25 ∙
= 0.25 ∙ 8 = 2
(3.6)
Unit clearance
∗=
2
(3.7)
∗= = 0.25
8
Heel circle diameter
= − 2 ∙ ∙ 1 + ∗
= 192 − 2 ∙ 8 ∙ 1 + 0.25
(3.8)
= 172
31. FSI BUT BACHELOR THESIS Sheet 31
Tooth thickness
= 0.5 ∙ ∙
= 0.5 ∙ ∙ 8 = 12.566
(3.9)
Tooth gap width
= 0.5 ∙ ∙
= 0.5 ∙ ∙ 8 = 12.566
(3.10)
Tooth head height
ℎ =
ℎ = 8
(3.11)
Tooth heel height
ℎ = 1.25 ∙
ℎ = 1.25 ∙ 8 = 10
(3.12)
Tooth height
ℎ = ℎ + ℎ
ℎ = 8 + 10 = 18
(3.13)
a) Rolling milling Tool:
- milling cutter for involute gearing KHSS-E, PM, ČSN 22 2551, viz.
Giant. 3.3
Giant. 3.3 Rolling mill4
Cutter parameters :
∅Dand= 125 mm
∅d = 40 mm
LF= 132 mm
x = 5 mm
m = 8
α = 20°
number of tooth grooves = 10 f
of= 0.96 mm
inC= 20.6 mm∙min-1
32. FSI BUT BACHELOR THESIS Sheet 32
Total machine time :
= ∙ ∙
∙ ∙
(3.14)
L…… total milling length z……
number of workpiece teeth
and……. number of machining chips per clamping fof….
cutter feed nw….. number of revolutions of the cutter uw
...number of milling operations (1)
= + + + (3.15)
b…… tooth width of the workpiece ln
….. ramp up
lMr……course
lof……safety distance for β = 0 to 5°
Giant. 3.4 Graphic representation of the total pathL tools in AutoCad
2009
= 29.5 + (37.6 + 3) + 2.6 + 3.5 = 76.2
Note : rise length lnand the course lMris given by the dimension of the concrete
gearing tools.
Cutter speed :
=1000 ∙
∙
(3.16)
1000 ∙
∙
1000 ∙ 20.6
∙ 125
= = = 52.4 −1
The total time will be :
76.2 ∙ 24 ∙ 2
0.96 ∙ 52.4 ∙ 1
3657.6
50.3
= = = 72.7
33. FSI BUT BACHELOR THESIS Sheet 33
b) Milling by splitting method
Since a real gear has 24 teeth, the direct division method is used. A
universal dividing device can be used for direct division. For this purpose, a
dividing disc with 24 holes is mounted on the head of the dividing spindle of the
device instead of the dividing disc with notches, which is used in the manual
dividing device. It can therefore be divided directly by removing the 1 : 40 worm
gears from the engagement and without using three interchangeable dividing
discs with holes at 2, 3, 4, 6, 8, 12 and 24 equal pitches.5
Giant. 3.5 Universal dividing device with three replaceable and one non-replaceable
dividing disc with 24 holes5
Calculation of the dividing device :
=24=24= 1 -The dividing handle is turned once by 360°.
24
Tool:
- disc shaped cutter for involute gearing m8 x 20, ČSN 22 2510, viz. Giant.
3.6
Giant. 3.6 Disc shaped cutter6
Cutter parameters :
∅Dand= 112 mm
∅d = 32 mm
s = 28 mm
z = 12
34. FSI BUT BACHELOR THESIS Sheet 34
Fof= 0.05 mm
inC= 20.6 mm∙min-1
Total machine time :
=
∙
∙ ∙ ∙
(3.17)
L…… total milling length z…… number
of workpiece teeth zF……number of
cutter teeth fof…. cutter feed nw…..
number of revolutions of the cutter u
w...number of milling operations (1)
= + + (3.18)
b……tooth width of the workpiece ln
….. ramp up
lMr……course
Giant. 3.7 Graphic representation of the total pathL tools in AutoCad
2009
= 29.5 + (42.5 + 3) + 3.5 = 78.5
The cutter speed is determined according to relation 3.16 :
1000 ∙
∙
=
1000 ∙ 20.6
∙ 112
= = 58.5 −1
The total time will be :
78.5 ∙ 24
0.05 ∙ 58.5 ∙ 12 ∙ 1
1884
35.1
= = = 53.7
35. FSI BUT BACHELOR THESIS Sheet 35
3.2 Calculation of an imaginary wheel with fewer teeth
Since it is a gear wheel with the same module, it is obvious that the different
values from the real wheel will only be in the diameter of the pitch circle, the
diameter of the base circle, the diameter of the head circle and the diameter of the
heel circle. Formulas 3.3, 3.4, 3.5 and 3.8 are used to calculate dimensions.
Calculation of wheel dimensions:
Pitch circle diameter = 8
∙ 18 = 144
The diameter of the base circle
= 8 ∙ 18 ∙ 20° = 135.316
Diameter of head circumference
= 144 + 2 ∙ 8 = 160
Heel circle diameter
= 144 − 2 ∙ 8 ∙ 1 + 0.25 = 124
a) Rolling milling
The cutting conditions of the tools are the same as in subsection 3.1 and also
the total machined length will remain the same, the only value that differs from the
real gear is the number of teeth.
Determination of machine time according to relation 3.14 :
∙ ∙
∙ ∙
=
76.2 ∙ 18 ∙ 2
0.96 ∙ 52.4 ∙ 1
2743.2
50.3
= = = 54.5
b) Milling by splitting method
The indirect division method is used here. We divide indirectly by
including the transmission gear. Such a gear consists of a worm and a worm
wheel, the ratio of which is usually 1:40.
The worm gear splitter works as follows:
The dividing movement is achieved by the dividing crank, which is connected to the
screw shaft. At the same time, a pin located in the handle of the dividing handle fits into the
holes of the dividing disc, which ensures the correct setting of the spacing. The dividing disc is
held in position by a locking pin. The circular spacing of the holes of the three dividing discs
usually has the following number of holes:5
36. FSI BUT BACHELOR THESIS Sheet 36
1.
2.
3.
15, 16, 17, 18, 19, 20
21, 23, 27, 29, 31, 33
37, 39, 41, 43, 47, 49
40 40
18
4
18
= = = 2 +
Giant. 3.8 Dividing disc5
Determination of machine time according to relation 3.17 :
∙
∙ ∙ ∙
=
78.5 ∙ 18
0.05 ∙ 58.5 ∙ 12 ∙ 1
1413
35.1
= = = 40.3
3.3 Calculation of an imaginary wheel with more teeth
The procedure for determining wheel dimensions and machine production times is the same
as in subsection 3.2.
Calculation of wheel dimensions:
Pitch circle diameter = 8
∙ 26 = 208
The diameter of the base circle
= 8 ∙ 18 ∙ 20° = 195.456
Diameter of head circumference
= 208 + 2 ∙ 8 = 224
Heel circle diameter
= 208 − 2 ∙ 8 ∙ 1 + 0.25 = 188
a) Rolling milling
Determination of machine time according to relation 3.14 :
∙ ∙
∙ ∙
=
76.2 ∙ 26 ∙ 2
0.96 ∙ 52.4 ∙ 1
3962.4
50.3
= = = 78.8
37. FSI BUT BACHELOR THESIS Sheet 37
b) Milling by dividing method
In this case, the indirect division method is again used here.
40 40
26
14
26
= = = 1 +
Determination of machine time according to relation 3.17 :
∙
∙ ∙ ∙
=
78.5 ∙ 26
0.05 ∙ 58.5 ∙ 12 ∙ 1
2041
35.1
= = = 58.1
3.4 Graphical evaluation
It follows from the formulas that the course of the graphic expression is linear, since the
only variable here is the number of teeth. That is, the total machine time is directly proportional to
the number of milled teeth of the workpiece.
Tab. 3.1 Calculated machine times
Number of teeth
wheels
Rolling method
tAS[minutes]
Divisive method
tAS[minutes]
18
24
26
54.5
72.7
78.8
40.3
53.7
58.1
Graphic expression:
Time dependence on the number of teeth
85
80
75
70
65
60
55
50
45
40
35
30
rolling milling
way
milling with dividers
way
18 19 20 21 22 23 24 25 26
number of teeth
Giant. 3.9 Graphic dependence of machine time on the number of machined teeth
machine
time
t
AS
[minutes]
38. FSI BUT BACHELOR THESIS Sheet 38
CONCLUSION
This bachelor's thesis gives a comprehensive overview of the manufacturing
methods and calculations of the dimensions of gears. The entire issue is divided into
subchapters according to the type of gearing (spur gears with straight and bevel
teeth, bevel gears with straight, bevel and curved teeth).
The practical part of the work was a comparison of the production methods
for the typed gear wheel by rolling milling and splitting milling. It was a wheel of
a relatively large module (8) with 24 teeth and two imaginary wheels that differed
only in the number of teeth (one imaginary gear wheel had fewer and the other
more teeth, compared to the real wheel).
After calculating the dimensions of the wheels and the total machine times of production,
the course of these machine times was graphically shown depending on the number of teeth of the
wheel. It follows that it is a linear course, the result of only changes in the number of teeth on the
given wheels. This is due to the fact that the same cutting conditions of the tools can be used up to
a certain number of teeth (30). If the number of wheel teeth differed by larger differences, then the
cutting conditions such as feed per tooth fofand cutter speed nwwere different. In practice, it is
known that the greater the number of machined teeth, the lower the revolutions of the cutter.
39. FSI BUT BACHELOR THESIS Sheet 39
LIST OF SOURCES USED
1. KOCMAN, K. and PROKOP, J.Machining technology. Brno: Akademické
nakladatelství CERM, 2005. 270 pp. ISBN 80-214-3068-0.
2. Gear machining.NATIONAL STANDARDS AND NORMS - Uniform norms.
Edition I. Prague 1964. 209 pp. CNN 10-25-0-0/1
3.S800/1200/1600/2000[online]. 2010 [cit. 2010-05-26]. SAMPUTENSILI.
Available of WWW:
<http://www.samputensili.com/media/SU/Machines/S900-
2000/S_800_S_1200_S_1600_S_2000_en.pdf >.
4.Custom production of gearing tools, both special and standard [online].
2010 [cit. 2010-05-26]. KASIKTOOLS. Available from WWW: <http://
www.kasiktools.cz/files/katalog.pdf >.
5.Division of the circumference of a circle[online]. 2001 [cit. 2010-05-26]. PAICHL, J.
Available from WWW: <http://www.paichl.cz/paichl/knihy/Schulze_10.htm >.
6.E-shop of milling tools[online]. 2010 [cit. 2010-05-26]. MT Tools. Available
from WWW: <http://www.i-frezy.cz/i-frezy/eshop/11-1-Tvarovekotoucove-
frezy/48-3-Na-evolventni-ozubeni-kol/5/1069-CSN22-2510-modulova-
freza- m8x20-c1 >.
7.Machine tools[online]. 2010 [cit. 2010-05-26]. TOS as a member of the
CTYGROUP group. Access WWW:
<http://www.tosas.cz/lang/produkty/ozubarenske-stroje >.
8.HG series gear centers[online]. 2006 [cit. 2010-05-26]. SAMPUTENSILI.
Available of WWW:
<http://www.samputensili.com/nqcontent.cfm?a_id=12980&lang=uk >.
40. FSI BUT BACHELOR THESIS Sheet 40
LIST OF ABBREVIATIONS AND SYMBOLS USED
Abbreviation/Symbol
b
C
C*
d
dand
db
dF
Fof
h
hand
hF
and
ln
lMr
lof
m
nO
nw
with
witht
t
Unit
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
-
mm
mm
mm
-
min-1
min-1
mm
mm
mm
min
-
mm∙min-1
Description
the width of the wheel teeth
head clearance
unit clearance
pitch circle diameter
head circle diameter
base circle diameter heel
circle diameter
feed per tooth
tooth height
tooth head height
tooth heel height
number of chips per run-up
clamping
overrun
safety distance module
workpiece speed
cutter speed
feed direction
tooth thickness
tooth height
machine time
number of milling operations
cutting speed
the number of teeth of the workpiece
the number of cutter teeth
computer numerical control
cutter diameter
total machined length
length of the milling cutter
tooth pitch
radius
angle of engagement
tool position adjustment angle
tool position deflection angle
Ludolf number
tAS
atw
inC
of
ofF
CNC
Dand
L
LF
P
R
a
β
λ
π
-
-
mm
mm
mm
mm
mm
°
°
°
-
-
-
-
-
-
-