Advance Machining Processes

Unit -I
Broaching, Gear and Thread Manufacturing
Process
Gear Manufacturing Process
• Session Topics
– Types of Gears with its applications
– Terminology of Gears
– Process Principle of Gear Manufacturing Process
• Gear Blanking
• Gear Rolling
• Gear Forming
• Gear Milling
– Gear Teeth finishing Processes
Types of Gears and Its Applications
Classification of Gears
Classification of Gears
Spur Gears
General:
Spur gears are the most commonly used gear type. They
are characterized by teeth which are
perpendicular to the face of the gear. Spur gears are by far
the most commonly available, and are generally the
least expensive. The basic descriptive geometry for a spur
gear is shown in the figure

Advantages: Spur gears are easy to find, inexpensive, and

efficient.

Limitations: Spur gears generally cannot be used when a

direction change between the two shafts is required.
 Helical Gears
General:
• Helical gears are similar to the spur gear except that the
teeth are at an angle to the shaft, rather than parallel to it
as in a spur gear.
• The resulting teeth are longer than the teeth on a spur
gear of equivalent pitch diameter. The longer teeth cause
helical gears to have the following differences from spur
gears of the same size:
• Tooth strength is greater because the teeth are longer,
• Greater surface contact on the teeth allows a helical gear
to carry more load than a spur gear
• The longer surface of contact reduces the efficiency of a
helical gear relative to a spur gear
 Helical Gears
• Helical gears may be used to mesh two shafts that are not parallel, although they are still
primarily use in parallel shaft applications. A special application in which helical gears are
used is a crossed gear mesh, in which the two shafts are perpendicular to each other
• The basic descriptive geometry for a helical gear is essentially the same as that of the spur
gear, except that the helix angle must be added as a parameter.
• Advantages: Helical gears can be used on non parallel and even perpendicular shafts, and
can carry higher loads than can spur gears
• Limitations: Helical gears have the major disadvantage that they are expensive and much
more difficult to find. Helical gears are also slightly less efficient than a spur gear of the
same size (see above).
• .
Helical Gears
 Bevel Gears
General:
• Bevel gears are primarily used to transfer power between intersecting shafts.
• The teeth of these gears are formed on a conical surface.
• Standard bevel gears have teeth which are cut straight and are all parallel to the
line pointing the apex of the cone on which the teeth are based.
• Spiral bevel gears are also available which have teeth that form arcs.
• Hypocycloid bevel gears are a special type of spiral gear that will allow
nonintersecting, non-parallel shafts to mesh.
• Straight tool bevel gears are generally considered the best choice for systems with
• speeds lower than 1000 feet per minute: they commonly become noisy above this
point.
• One of the most common applications of bevel gears is the bevel gear differential,
• Advantages: Excellent choice for intersecting shaft systems
• Limitations: Limited availability. Cannot be used for parallel shafts. Can become
• noisy at high speeds.
Bevel Gears
Bevel Gears
Worm Gears
General:
• Worm gears are special gears that resemble screws, and can be used to drive spur gears or
helical gears.
• Worm gears, like helical gears, allow two non-intersecting 'skew' shafts to mesh.
Normally, the two shafts are at right angles to each other. A worm gear is equivalent to a
V-type screw thread. Another way of looking at a
• worm gear is that it is a helical gear with a very high helix angle.
• Worm gears are normally used when a high gear ratio is desired, or again when the shafts
are perpendicular to each other.
• One very important feature of worm gear meshes that is often of use is their irreversibility
: when a worm gear is turned, the meshing spur gear will turn, but turning the spur gear
will not turn the worm gear. The resulting mesh is 'self locking', and is useful in ratcheting
mechanisms.
Worm Gears
• Worm gears are normally used when a high gear ratio is desired, or again when the
shafts are perpendicular to each other. One very important feature of worm gear
meshes that is often of use is their irreversibility : when a worm gear is turned, the
• meshing spur gear will turn, but turning the spur gear will not turn the worm gear. The
resulting mesh is 'self locking', and is useful in ratcheting mechanisms.
• Limitations: Low efficiency. The worm drives the drive gear primarily with slipping
motion, thus there are high friction losses.
• Advantages: Will tolerate large loads and high speed ratios. Meshes are self locking
(which can be either an advantage or a disadvantage).
Worm Gears
Applications of Gears
Terminologies of Gears
Gear Terminologies

• Reference line Gear Teeth

• Pitch • Number of teeth denotes the number
• Tooth thickness of gear teeth.
• Addendum They are counted as shown in the
Figure 2.3. The number of teeth of this
• Dedendum
gear is 10
• Tooth Depth
• Tooth tip
• Tooth root
Gear Terminologies
• Reference line
• Pressure angle
• Normal reference line
• Pitch
• Tooth surface
• Root surface
• Top land
Gear Terminologies -Diameter of Gears
(Size)
• The size of gears is determined in
accordance with the reference
diameter (d) and determined by
these other factors; the base circle,
Pitch, Tooth Thickness, Tooth Depth,
Addendum and Dedendum.

• Addendum
• Dedendum
• Root diameter
• Reference diameter
• Tip diameter
Centre Distance

• When a pair of gears are meshed

so that their reference circles are
in contact, the center distance (a)
is half the sum total of their
reference diameters

• Centre distance (a)

a = (d1+d2) / 2
Gear Meshing
• Tip diameter
• Reference diameter
• Base diameter
• Root diameter
• Face width
• Tooth thickness
• Reference pitch
• Centre line
• Pressure Angle
• Backlash
• Tooth depth
• Addendum
• Dedendum
• Centre distance
• Tip and Root Clearance
Tip and Root Clearance
Gear Manufacturing Processes
Gear Manufacturing Process
Gear Teeth cutting
Forming and Generating methods of Gear cutting
Gear Cutting by Forming
Gear Forming on Milling Machine
Gear Cutting by Shaping, Planning and Slotting
Gear Planning

• In this method, gear cutting is done by a

rack shaped cutter called rack type
cutter.
• The process involves rotation (low rpm)
of the gear blank as the rack type cutter
reciprocates along a vertical line.
• Cutting is done only in the downward
stroke, the upward stroke is only a
return movement.
Gear Shaping Process
Gear Shaping Process

• This process uses a pinion shaped

cutter carrying clearance on the
tooth face and sides and a hole at
its center for mounting it on a stub
arbor or spindle of the machine.
• The cutter is mounted by keeping
its axis in vertical position.
• It is also made reciprocating along
the vertical axis up and down with
adjustable and predefined
amplitude
Gear Shaping Process
Gear Shaping Process
Gear Cutting using rack type cutter
Gear Cutting by Broaching
Gear Hobbing
Gear Hobbing

• In this process, the gear blank is rolled

with a rotating cutter called hob.
• Gear hobbing is done by using a multipoint
cutting tool called gear hob.
• In gear hobbing operation, the hob is
rotated at a suitable rpm and
simultaneously fed to the gear blank.
• The gear blank is also kept as revolving.
• Rpm of both, gear blank and gear hob are
so synchronized that for each revolution of
gear hob the gear blank rotates by a
distance equal to one pitch distance of the
gear to be cut.
• Motion of both gear blank and hob are
maintained continuously and steady.
Gear Hobbing
Gear Hobbing
Gear Teeth Finishing Processes
Gear Teeth Finishing Processes

• GEAR SHAVING
• ROLL FINISHING OF GEAR TOOTH
• GEAR BURNISHING
• Gear Grinding
• Lapping of a Gear
• GEAR HONNING
Gear Shaving
• Gear shaving is a process of finishing of gear tooth by running it at very high rpm in
mesh with a gear shaving tool. A gear shaving tool is of a type of rack or pinion having
hardened teeth provided with serrations. These serrations serve as cutting edges.
 Roll Finishing Of Gear Tooth

• This process involves use of two hardened rolling dies containing very
accurate tooth profile of the gear to be finished. The gear to be finished is Yet
in between the two dies.
Gear Burnishing

• The gear to be finished is mounted on a vertical reciprocating shaft and it is kept in

mesh with three hardened burnishing compatible gears. The burnishing gears are fed
into the cut gear and revalued few revaluations in both the directions. Plastic
deformation of irregularities in cold state takes place to give smooth surface of the gear.
Gear Grinding

• In this operation abrasive grinding wheel of a particular shape and geometry

are used for finishing of gear teeth. Gear to be finished is mounted and
reciprocated under the grinding wheel. Each of the gear teeth is subjected to
grinding operations this way.
Lapping of a Gear

• The process of lapping is used to improve surface finish of already made

teeth. In this process the gear to be lapped is run under load in mesh
with cast iron toothed laps. Abrasive paste is introduced between the
teeth.
• It is mixed with oil and made to flow through the teeth. One of the
mating members (either gear or lapping tool) is reciprocated axially along
with the revaluations.
Gear Honning

• It is used for super finishing of the generated gear teeth. Honing

machines are generally used for this operation.
• The hones are rubbed against the profile generated on the gear tooth.
Gear lapping and gear honing are the lost finishing operations of a gear
generation process.