Suncone gears slide

BY:
MUHAMMAD ASYRAF BIN ISMANIZAN (A167554)
NURUL SYAZWANI BINTI SAHARI (A169841)
AMIER BAZLIE BIN JOHARI (A170279)
MOHAMAD SYAFIQ SALMAN BIN AZMAN (A167681)
Department of Mechanical & Manufacturing Engineering
Faculty of Engineering & Built Environment
Universiti Kebangsaan Malaysia
“MANUFACTURING PROCESSES OF GEARS”

With guidance from LECTURERS
PROF DR.ANDANASTUTIMUCHTAR
Dr.nabilah afiqah binti mohdradzuan
DR.NASHRAH HANI BINTI JAMADON
Email: muchtar@ukm.edu.my
Email: afiqah@ukm.edu.my
Email: nashrahhani@ukm.edu.my

WHAT ARE GEARS?
01
-Introduction about
Gears/Cogwheel
-Applications in industry
HOW ITS MADE
02
-Explains how gears are
made in the industry
analysis
03
-Materials used in making the gears
- Properties of the material
conclusion
04
-Best method in
manufacturing gears

Team members
MUHAMMADASYRAF BIN ISMANIZAN [A167554]
- SECOND YEAR MECHANICAL ENGINEERING STUDENT
- Department of Mechanical & Manufacturing Engineering
- Email: A167554@siswa.ukm.edu.my
MOHAMADSYAFIQ SALMAN BIN AZMAN [A167681]

Team members
Amier bazlie bin johari [A170279]
NURUL SYAZWANI BINTI SAHARI [A169841]

— TONY BLAIR
“I can only go one way. I’ve not got
a reverse gear. ”
Ref:https://www.azquotes.com/quotes/topics/gears.html
QUOTE OF THE DAY

WHAT ARE GEARS?
01
“...a machine part which rotates that has either cut teeth or
inserted teeth that combines with another toothed part in order
to create and transmit torque...”
- Wikipedia
Ref: https://en.wikipedia.org/wiki/Gear

INTRODUCTION ABOUT GEARS
● Mechanism that engage together via teeth are called gears or some
people might be familiar with the word, cogwheel. They are often
used in machinery to transmit rotary motion from one shaft to
another.
● Gears are commonly found on machines where they are generally,
either mounted or sometimes connected to another parts through
bases or even shafts. This is for them to be able to transmit the
rotary motion as mentioned.
● Although gears are known as simple machines, they are a very
important element in the world of engineering nowadays, and are
usually identified by Mechanical Engineers.
● Gears are designated by two main characteristics or items which are
the radius and the number of teeth they have.
Ref:https://www.teachengineering.org/lessons/view/umo_challenges_lesson02
Ref:https://www.creativemechanisms.com/gears

RADIUS VS TEETH
Different particular section of
the gear has differently
defined gear radius. But, the
most relevant measurement
for radius are these two,
which are the root radius and
addendum radius. Other
terminology used in
designing gears also includes
Pitch, Tooth Thickness,
Dedendum and Tooth root.
Teeth in gears are very
crucial as they determine if
the pairing gears can mesh
together. Hence, the Pitch
must be the same for all
mating pairs. The distance
between the equivalent
points of adjacent teeth are
known as the Pitch. A good
mesh between mating gears
helps prevent slipping and
can also increase
efficiencies as well.
RADIUS TEETH
Ref:https://khkgears.net/new/gear_knowledge/abcs_of_gears-b/basic_gear_terminology_calculation.html
Ref:https://gearsolutions.com/features/determining-gear-efficiency/

TYPES OF GEARS
● There are many types of gears invented to suit the needs of different
machinery and to perform different functions. The most common ones are
the helical gears, spur gears, straight and spiral bevel gears and also the
hypoid gear.
● Gears has been classified through various methods in the industry. The most
popular classification of different types of gears is by looking at different
position of the gear axis. While on the other hand, the method of
manufacturing the gear, the tooth profile and material used can also play a
role in determining the type of the gear produced.
● The most common and widely used type of gear is the Spur Gear as they can
achieve very high accuracy along with easy production processes
● There are also many other types of gears out there in the industry besides
what has been mentioned above
Ref:https://www.sciencedirect.com/science/article/abs/pii/1350630796000088
Ref:https://khkgears.net/new/gear_knowledge/introduction_to_gears/types_of_gears.html

SPUR GEARS
● Amongst all kind of gears, Spur
gears are the most common
type of gear
● The teeth are designed to be
protruded outwards from its
perimeter
● Powers are transmitted
through shafts that are parallel
in position.
● Disadvantages of using this
gear includes noises being
produced due to the teeth of
gears colliding with each other.
Photo
courtesy
Emerson
Power
Transmission
Corp.
Ref:https://www.rexnord.com/blog/articles/types-of-gears
Ref:https://www.thomasnet.com/articles/machinery-tools-supplies/understanding-gears/
Ref:https://science.howstuffworks.com/transport/engines-equipment/gear2.htm

HELICAL GEARS
● Noise reduction can be obtained by
ultilizing helical gears. The teeth tend
to start at one end and gradually
moves to the rest of the teeth as it
rotates since they are cut at an angle
● Provides smooth operation alongside
of less impact loading being applied
on the teeth
● High cost of manufacturing due to the
complexity cutting the teeth at an
angle
Photo
courtesy
Emerson
Power
Transmission
Corp.
Ref:https://science.howstuffworks.com/transport/engines-equipment/gear2.htm

SPIRAL BEVEL GEARS
● Has the same teeth cutting like
Helical gears to aid in noise
reduction.
● Has better strength and
oscillation compared to
Straight Bevel Gear.
● Disadvantage with using Spiral
Bevel Gear is regarding the
axial thrust load.Hence, this
gear needs a proper bearing
location and firm support to it.
Photo by
Medital.com
Ref:https://www.medital.com/products/spiral-bevel

INDUSTRIAL
APPLICATION
OF GEARS

SPUR GEAR
INSIDE THE GEARBOX OF A WASHING
MACHINE TO SPIN THE TUB.
Ref:https://home.howstuffworks.com/washer6.htm
AS SIMPLE AS INSIDE THE MECHANISM OF
A CLOCK.
Video credits goes to :https://www.youtube.com/watch?v=lnTlYZ1JhM8

HELICAL GEAR
USED IN HIGH SPEED APPLICATIONSUCH
AS THESE TWO, GAS AND STEAMTURBINES
as these gears are highly durable
that they can withstand high load
and also ensure less wear at any
time given since the load are
distributedover several teeth.

SPiral bevel GEAR
Fighter jets with up to 16,000 rpm jet
application.
DEFENCE TANKS WITH HIGH POWER
DENSITY.
Ref:https://bevelgearsindia.com/applications/
Video credits goes to :https://www.youtube.com/watch?v=ckmh6FvHidQ
Video credits goes to :https://www.youtube.com/watch?v=GaxMKNHwEeA

References:
Mechanisms, C. (n.d.). Gears. Retrieved July 10, 2020, from
https://www.creativemechanisms.com/gears
Nair, S., Samarth, P., & Nair, S. (2020, April 25). What Are Gears and What Do They Do?
- Lesson. Retrieved July 9, 2020, from
https://www.teachengineering.org/lessons/view/umo_challenges_lesson02
Relly Victoria Petrescu - Narcisa Popescu, By, -, Relly Victoria Petrescu is a lecturer
in the Department of Descriptive Geometry and Engineering Graphics at the
University Politehnica of Bucharest., Petrescu, R., Is a lecturer in the Department of
Descriptive Geometry and Engineering Graphics at the University Politehnica of
Bucharest., . . . Is an assistant professor in the university’s in Department of
Mechanisms and Robots. (2019, November 21). Relly Victoria Petrescu. Retrieved July
19, 2020, from https://gearsolutions.com/features/determining-gear-efficiency/

References:
Basic Gear Terminology and Calculation. (n.d.). Retrieved July 6, 2020, from
https://khkgears.net/new/gear_knowledge/abcs_of_gears-
b/basic_gear_terminology_calculation.html
Types of Gears: Free Gear Guide. (n.d.). Retrieved July 11, 2020, from
https://khkgears.net/new/gear_knowledge/introduction_to_gears/types_of_gears.
html
Fernandes, P. (1996). Tooth bending fatigue failures in gears. Engineering Failure Analysis, 3(3), 219-
225. doi:10.1016/1350-6307(96)00008-8
https://www.sciencedirect.com/science/article/abs/pii/1350630796000088

References:
Ronquillo, R. (n.d.). How Gears Work - Different Types of Gears, their Functions,
Mechanisms and Applications. Retrieved July 16, 2020, from
https://www.thomasnet.com/articles/machinery-tools-supplies/understanding-
gears/
The Different Types of Gears. (n.d.). Retrieved July 10, 2020, from
https://www.rexnord.com/blog/articles/types-of-gears
Industrial Applications of Bevel Gears. (n.d.). Retrieved July 10, 2020, from
https://bevelgearsindia.com/applications/
Nice, K. (2000, October 31). How Washing Machines Work. Retrieved July 17, 2020,
from https://home.howstuffworks.com/washer6.htm

HOW GEARS ARE MADE?
02
Manufacturing of gears is step-by-step processes of turning
raw materials to a function gear. It required several
processing in operations sequential stages. It includes
performing gear blanks, gear teeth production and finishing.
Ref: https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-32.pdf

STEP 02 STEP 04STEP 03 STEP 05
Material selection
Selected materials will
be processed into a
blank
Performing Gear
Blank
Materials is cut a
bigger size of desired
dimensions
Production of
Gear Teeth
Various of processes
can be used to generate
the actual dimension of
the gear teeth.
STEP 01
Finishing
A proper finish is
necessary in order to
have a clean and
longer gear lifespan.
STEP 06
Quality Control
A finished product must
be inspected to decide
if any needs for
corrective actions
Packaging and Delivery
A final product is ready to
deliver to the customer

casting
Various casting processes can
generate gear blanks includes
sand casting, metal mould
casting, die casting,
centrifugal casting, etc.
rolling
Cold rolling used to
produce straight and
helical teeth of disc or rod
type external steel gears.
Powder
metallurgy
Powder metallurgy make a
small high strength spur,
bevel or spiral gears. It is
less expensive in a large
production quantities.
Picture from:
https://nptel.ac.in/content/storage2/courses/1
12105127/pdf/LM-32.pdf
Gear MANUFACTURING PROCESS
Picture from:: https://gearmotions.com/powdered-metal-
gears/
Picture from:
http://theinfoscience.blogspot.com/2016/01/what-is-
casting.html
Same area
Blank
diameter

GEAR MANUFACTURING PROCESS
Extrusion
Extrusion process usually
produce high quality small
metallic or non metallic
external gears in large quantity.
Plastic Moulding
By injection moulding, plastic
gears with or without metal
core are manufactured.
Moderately accurate and less
noise gears and used under
light loads.
Blanking in Press tool
Blanking from sheets is done
to produce mass production
of small and thin metallic
gears. Usually, this kind of
gears produced by blanking is
used for clocks, watches etc.
Picture from: http://tdimolding.com/plastic-injection-
molded-gears/
Picture from:
http://www.zndxzk.com.cn/down/2014/01_
znen/08-p0050-e121549.pdf
Picture from:
https://www.open.edu/openlearn/science-maths-
technology/design-
innovation/manufacturing/content-section-3.8
container
billet
die
ram
punch
workpiece
helical gear
counterpunch die
blank holder
F

MACHINING:
generatiNG PRINCIPLE
Gear teeth produced by rotating
the gear blank in contact with
the rotating cutter. The cutter
axis is parallel to the gear face.
It will enter and exits the blanks,
while moderately feed into the
gear blanks to a desired
depths.
shaping
hobbing
Gear teeth produced by series of
cuts using a hob (helical fluted
cutting tools). Hob will axially fed
the gear face and only can
produce external gears teeth.
Hob
Pictures from:
https://nptel.ac.in/content/storage2/courses/112105
127/pdf/LM-32.pdf

MACHINING:
Forming principle
gashing
miling
Use a multi-edge cutter that
rotates into the gear blank.
It mills to produce gear
teeth one by one.
broaching
Use a multi toothed cutting tool
called a broach. Usually used for
producing internal gears. The
gear blank is pushed into the
broach to remove the internal of
the blank. The depth of cut
increases with each tooth.
Picture from: https://www.engineeringenotes.com/manufacturing-
science/material-removal-process/types-of-material-removal-
process-multipoint-abrasive-and-finishing-manufacturing-
science/52188
A process used on heavy duty
milling machine to produce large
coarse pitch on the blanks

Gear finishing
Gear shaving
A rotary gear shaving that
removes small amounts of
working surfaces of the gear
teeth. Used to minimize the gear
noise as it improves the surface of
gear teeth.
shaver
Gear burnishing
A machined gear teeth are
polished by cold plastic flow to
refine the gear surface. The gear is
rolled under pressure with three
hardened master gears of high
accuracy and finish.
Picture from:
https://encyclopedia2.thefreedictionary.com/G
ear-cutting+Machine
https://www.semanticscholar.org/paper/Perfor
mance-Improvement-of-Roller-Burnishing-A-
Yadav-
Ghatge/973dc675ac3f5e5ee2c41cbb3848310
shaver

Gear finishing
Gear lapping
Use a lapping tools to produce a high accuracy to
gear teeth while applying a fine-grained abrasive
between the workpiece and and a lapping plate.
Gear grinding
A critical step to get a high precision gear. It is
mainly performed after the material undergoes the
heat treatment process. A grinded teeth gear will
produce low noise and evenly wear.
wheel
gear
Picture from: https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-32.pdf
https://www.amtechinternational.com/gear-lapping-grinding-
services/https://www.amtechinternational.com/gear-lapping-grinding-services/

References:
Gear Manufacturing Methods
https://www.youtube.com/watch?v=B0XSsa79Y1w
Gears - How its Made
https://www.youtube.com/watch?v=XZgsV0AZJJ0&t=125s
John P. Dugas (1986), The Process of Gear Shaving, National Broach & Machine, A Division
of Lear Siegler, Inc
https://www.geartechnology.com/articles/0186/The_Process_of_Gear_Shaving/
Module 7 - Screw threads and gear manufacturing methods
https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-32.pdf
Gear Grinding
https://gearmotions.com/manufacturing/gear-grinding/

what materials are used in the
making of gear ?
03
Gears basically are made of all sorts of materials as example
steel, brass, bronze, cast iron, ductile iron, aluminum,
powdered metals, and plastics.

BRONZE
ALUMINIUM
BRASSSTEEL
CAST IRON
Ref : https://my.rs-online.com/web/p/worm-wheel-gears/5216979/
Ref : http://www.bestagear.com/worm_gear/worm_gear_258.html
Ref : https://www.indiamart.com/proddetail/aluminum-gear-13443429897.html
Ref : https://www.okchem.com/showroom/cast-iron-gear-wheel.html
Ref : https://www.directindustry.com/prod/maedler-gmbh/product-66929-1572034.html

Factors of material selection
01
02
03
cost
DURABILITY
strength

WHAT IS THE BEST MATERIAL FOR GEARS ?
Due to the ease of manufacturing and the variety of alloys available, metal alloys are
the most common material used for gears. Carbon or alloy steels are commonly used
due to their high strength values. These steels are heat-treated in order to achieve
the appropriate combination of toughness and tooth hardness.
Cast iron is also a common gear material due to its good wearing properties,
machinability, and the ease of producing complicated shapes via metal casting.
Worm gears tend to use phosphor bronze because of the material’s wear resistance
ability.
Ref : https://www.machinedesign.com/learning-resources/engineering-essentials/article/21834512/gears-look-to-the-future-for-
material

Conclusion
04
Best method in manufacturing gears and
local companies in Malaysia manufactures
gears

Best method in manufactures gears
● Broaching
Faster method to remove the material using the multi-tooth cutting tools that
called broach/gear blank
Conventional method used to make internal gear and pop broaching used to
make external broaching
● Milling
To generate gears shape
To produce large external/ internal gear the process called gashing
What is gashing?
Gashing is the rapid metal removal
● Heat-treatment
To make hardness requirement
● Finishing
To get a good and fine finishing
GEAR FORM- CUTTING

Mt gear & engineering service
sdn.bhd
Supply and fabricates every
kind of gears with a reasonable
pricing to private
corporate,SMI. And
government agencies
Specialized all kind of gears and
general engineering service
● Gear grinding
● Gear cutting
● Repairing gear box & service
gear box
● Undertake all type of Machinery
Job
Located at Sungai Pinang, Klang
https://mtgear.com.my/

Hydena automation sdn bhd
Established in March 2011
● 9800 types of gears (always in stock)
● Provides low price because of standardize
● CAD drawing / Techinical detail available for
all types of gears
● Their HQ at Japan have 75 years of
experience in gear manufacturing
Locate at Taman Perindustrian
Puchong,Puchong
http://www.hydena.com.my/

References:
GEAR EXPLANATION-
https://www.explainthatstuff.com/gears.html#:~:text=Similarly%2C%20in%20a%20car
%2C%20gears,increasing%20speed%20and%20changing%20direction
MATERIAL USE TO MAKE GEARS-
https://www.ukessays.com/essays/engineering/materials-used-for-making-gears.php
GEARS COMPANY-
https://mtgear.com.my/
http://www.hydena.com.my/khk-gear/

LINKED IN:
1) MUHAMMAD ASYRAF BIN ISMANIZAN
https://www.linkedin.com/in/muhammad-asyraf-
ismanizan-82bb391b2/
1) NURUL SYAZWANI BINTI SAHARI
https://www.linkedin.com/in/syazwani-sahari-7087151a1
1) AMIER BAZLIE BIN JOHARI
https://www.linkedin.com/in/amier-bazlie-ba6aa51b2/
1) MOHAMAD SYAFIQ SALMAN BIN AZMAN
https://www.linkedin.com/in/syafiq-salman-319b401b2/
YOUTUBE: https://youtu.be/QhnBznRRxiw
SLIDESHARE:

CREDITS: This presentation template was created by
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THANKS!

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