This document discusses various manufacturing processes including casting, forming, and machining. It provides examples of each process and describes how machining is used to manufacture a specific case study of compound gears. The document outlines the machining operations of facing, turning, drilling, boring, and hobbing used to shape the gear blanks and cut the gear teeth. References for further information on gear and machining process design are also provided.

1. ~VAIBHAV PARDESHI
Selection Of Manufacturing
Process

2. Manufacturing Process define as process of
conversely raw material in to products
encompass the design and manufacturing of
good using verious method , techniques like
man, Machine and Money
What is Manufacturing Process?

3. The term may refer to range of human activity, from
handicraft to high tech,but is most commonly applied to
industrial production in which raw material are
transformed into finished goods on latge scale.
Such finished goods may be used for manufacturing.
Product such as aircraft, household applieances, or sold
to wholesalers, who in turn sell them to retailers.
Manufacturing takes turns under all types of economic
systems.
In free market economy, manufacturing is usually
directed toward the mass production of product for sale
to consumers at a profit.
In mixed market economics, manufacturing occurs under
some degree of government regulation.
Importance Of Manufacturing

4. • Cost of product
• Assembly
• Processing
• Tools used
• Production rate
WHY TO STUDY-

5. • Required to convert a raw material
into finished and useful component
as per design.
• They can be classified as follows:
FORMING
CASTING
MACHINING
NEED OF MANUFACTURING PROCESS-

6. • Molten metal is poured in cavity and is allowed to solidify in a desired
shape.
• Tooling cost required is minimum.
• Post machining operations are required as surface finish is not
proper.
• Materials such as cast iron, aluminium, brass, bronze, etc. can be
casted.
• Example: Gearbox housings, crankshaft, cam shaft, etc.
CASTING-

7. • The metal is heated above recrystallization temperature for hot forming and
below the same for cold forming.
• The metal becomes plastic and can be formed to desired shape without
cutting of material ultimately saving the material.
• Example: connecting rod, bolts, pins, etc.
FORMING-

8. • Different types of cutting operations are performed on the
raw material.
• Most widely used manufacturing process as high precision
and accuracy can be obtained by this process.
• Facing, turning, boring, drilling, taper turning, milling,
shaping, etc. are some the cutting processes.
• Advanced machining operations can be performed on CNC
VMC and CNC HMC by using computer programs.
• Cost for this process is high as compared to casting and
forming.
MACHINING-

9. • Two gears on the same shaft are made as a
single unit.
• Both the gears are connected by a spindle.
• It reduces the complexity and time of
assembly.
• This component cannot be manufactured by
casting as the material used for this are of
plain carbon steel category which are not
suitable for casting.
• Forming is not the appropriate method as
gear tooth profiles demand higher accuracy
to have constant velocity ratio which cannot
be obtained by forming.
CASE STUDY
COMPOUND GEARS
OF

10. Machining is the best suitable process for
manufacturing of compound gears as material
used for the same i.e. plain carbon steel has
good machinability and even intricate shapes
like gear tooth profiles can be cut by different
machining operations.
• Addendum diameter of the large gear is
150mm.Hence the dia. Of the gear blank
purchased is 160mm.
• Calculations for the face width of the
gears resulted in overall length of gear
blank as 60mm.So the length of the blank
purchased is 70mm.
PLAN PROCESS

11. Facing operation is performed on both the
sides of the blank and reduce the blank
length to 60mm.
Turning operation is performed on the blank
to obtained the desired diameter of 150mm
bigger gear, again the same operation is
carried out to form small gear of diameter
100mm up to 40mm length.
Undercutting operation is carried out to give
the depth of 22.5mm to form the connecting
part of 10mm length.
FACING-
TURNING-
UNDERCUTTING-

12. Drilling operation is carried out to form a
hole of 18mm & further 33mm diameter to
insert the shaft.
Boring operation is performed to form the
hole of desired diameter of 35mm shaft.
Hobbing is a machining process for a gear
cutting, the teeth are progressively cut into
the work piece by a series of a cuts made
by cutting tool called Hob.
DRILLING-
BORING-
HOBBING-

13. • Design of machine V.B.Bhandari (operation, material,
keyway, module of gear)
• www.couplinganswer.com
(Broaching operation for keyway)
• https://encrypted-
tbn0.gstatic.com/images?q=tbn:ANd9GcSjRLK8Kv2HUv
f9OZ617VIuJ6OumGsHKK7u-A3d9Vvijwn8IwRuJA
References-

14. Thank you