1. S.H.JONDHALE POLYTHENIC DOMBIVLI WEST
DEPT. OF MECHANICAL ENGINEERING
A
PROJECT ON
ADVANCED MANUFACTURING PROCESS (22563)
SUBMITTED BY –
NAMESH KORKE
NIKHIL MEMANE
ROHAN AVHAD
SUMEET THAKRE
PRATIK KHANDEWAL
GUDIED BY-
PROF.PARAG BAGUL
2. Gear Manufacturing
The process of gear manufacturing involves a series of steps and techniques
that ensure the production of high-quality gears. In this presentation, we will
explore the different types of gears, the manufacturing process, and the
materials used, as well as recent advancements and future trends in gear
manufacturing technology.
3. Types of Gears and their Applications
1 Spur Gears
The most common type of gear used in industrial applications and machines. These gears
have straight teeth and are excellent at transmitting power between parallel shafts.
2 Helical Gears
These gears have angled teeth that allow for smooth and quiet gear operation. They are
often used in high-speed applications where noise reduction is critical.
3 Bevel Gears
These gears are used to transmit power at right angles. They are commonly found in
differential drives, steering systems, and other applications where changes in direction are
needed.
4 Worm Gears
These gears are used to transmit power between non-parallel shafts and are known for their
high reduction ratio. They are often used in applications where high torque is needed and
space is limited.
4.
5.
6. Gear Manufacturing Processes
Casting
Molten metal is poured into
a mold to create the gear
shape. After it cools, the
gear is removed, cleaned,
and finished.
Machining
The gear shape is cut out of
a solid piece of metal using
a lathe, milling machine, or
other cutting tools.
Forming
A metal blank is pressed
into a gear shape using a
die. The gear is then
removed, heat-treated, and
finished.
7.
8. Materials used in Gear Manufacturing
Metal Gears
Commonly made from steel,
bronze, or cast iron, metal
gears are known for their
strength and durability.
Plastic Gears
Lightweight and corrosion-
resistant, plastic gears are often
used in low-load and low-speed
applications.
Composite Gears
Made from a combination of
materials such as carbon fiber
and plastic, composite gears
offer high strength and low
weight.
Ceramic Gears
Known for their high resistance
to wear and corrosion, ceramic
gears are often used in high-
speed and high-temperature
applications.
9.
10.
11. Quality Control in Gear
Manufacturing
1 Dimensional Analysis
Verifying that the dimensions of the
gear are within allowable tolerances.
2 Magnetic Particle Inspection
Finding surface or subsurface
defects in the gear through magnetic
particle testing.
3 Hardness Testing
Ensuring that the gear's hardness
meets the required specifications.
4 Visual Inspection
Inspecting the exterior of the gear for
surface defects, cracks, or other
flaws.
12. Recent Advancements in Gear
Manufacturing Technology
3D Printing
The ability to print complex
gear geometries in a single
step using metal or plastic
powder, reducing
manufacturing time and costs.
Nanotechnology
The use of nanoscale materials
and structures to create
stronger, lighter, and more
durable gear materials.
Robotics and
Automation
The use of robots and
automated systems that can
perform gear manufacturing
tasks with greater precision
and speed.
13.
14.
15. Future Trends in Gear Manufacturing
1
Smart Gears
Gears that include sensors and other
electronics that collect data on gear
performance and health in real-time.
2
Green Manufacturing
Reducing the environmental impact of gear
manufacturing by using sustainable materials
and energy-efficient processes.
3
Integrated Design and
Manufacturing
A more streamlined and integrated approach to
gear design and manufacture that enables
faster prototyping, testing, and production.
16. Conclusion
Manufacturing Gears with Excellence
Gear manufacturing is a complex and precise
process that requires expertise, advanced
techniques, and continuous innovation to deliver
high-quality products that meet the demands of
modern industry.
Designing for the Future
As technology continues to evolve, the future of
gear manufacturing will be shaped by emerging
trends, new materials, and innovative design and
manufacturing processes that enable greater
efficiency, sustainability, and performance.
