Gear finishing Process

Grinding

Gear
Shaving
Honning

Types
Gear Burnishing
Lapping
 Grinding
Principle:-
• It is a finishing process to remove considerable amount of
the metal after heat treatment to obtain predetermined
quality gear.
• 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. There are three general
methods of gear grinding

1. Form wheel grinding

2. Generation grinding
3. Threaded wheel grinding
Cont..

Form wheel Generation Threaded wheel

grinding grinding grinding
 Shaving
Principle: -
• Gear shaving process can be linear or rotary. In the
linear type rack type cutter is used. While rotary
method employs a pinion cutter.
• The cutter teeth are serrated to form a series of
cutting edges.
• To obtained relative sliding action between the tooth
profile the work gear and shaving cutter are set up in
the gear shaving machine with cross axes.
• Due to the sliding action very small amount of material
from the gear tooth is removed and finished profile
surface is obtained.
Cont..
Shaving
Teeth
 Burnishing
• Principle: - The operation consists essentially of
rolling the work gear with one or several
burnishing gears whose teeth are very hard,
smooth and accurate. The latter gears are driven
by a motor.
 Gear Lapping
Principle:-
• It is the process of refining the gear element after the heat
treatment. The process is done by rotating the gear and the
lap tool as inter meshing gears, with abrasive compound
forced between the teeth.
• It is the process used for improving surface finish by
reducing roughness, waviness & other irregularities on the
surface.
• Material for lapping tool can be natural or artificial
abrasives depending on work piece material.
• Lubricant is used to hold or retain the abrasive grains
during operation. Lapping operation is done two methods
1. Hand lapping:- Work piece is held in hand & the motion of
the other enables the rubbing of two surfaces in contact,
this method is used for press dies, valve seats etc.
2. Machine lapping:- It is done to obtain highly finished surfaces on
work piece, like ball and roller bearings , engine parts.
Cont..
 Gear Honing
Principle
• It is a super finishing operation used for previously machined
surfaces.
• It is used for finishing internal cylindrical surfaces, drilled or
bored holes the tool is called as Hone which is made out of
bonded abrasive stone made in the form of stick.
• The tool moves back & fourth while rotating about its axis.
Honing operation can be done by two methods.
Cont..
 Differentiate
Sr No. Up Milling Down Milling
There is a tendency to lift the work
Forces are enough on job to press to press
1 piece so extra clamping force is
down. So no need of extra clamping forces
required
Cutter rotates against direction in which Cutter rotates in similar direction in which
2
the work being fed the work being fed
3 Cutting force varies from Zero to max. Cutting force varies from max to zero
Chip thickness varies from minimum to
4 Chip thickness varies from max to minimum
maximum
Higher surface finishing can be
5 Obtains lower surface finish
obtained
6 Use of cutting fluid is difficult Use of cutting fluid is easy
7 Job and tool movement is opposite Job and tool movement in same direction
direction

Sr No. Gear Hobing Process Gear Shaping

Generates teeth on gear by means of Reciprocating motion of the cutter based on
1
rotating cutter called as Hob. shaping process.
Hobbing produces a series of radial flats based on feed Shaping produces a series of straight line parallel to the axis
2 rate of Hob across the of the gear. Surface finish
work may be better.
3 It use as multipoint cutter Know as Hob. It uses a rack cutter or pinion cutter.
It is rapid, economical and highly
4 It required more time than Hobbing.
productive.
5 It cannot generate internal gear It can be used to produce internal gears also
 Differentiate
Sr. No. Honing Lapping
To get high degree of surface finish To get geometrical true surfaces, correct
1 as well as to correct the roundness, minor surface imperfections and improve
taper in the work. the dimensional accuracy.
Honing is slow speed finishing Lapping is low pressure, low speed
2
process. abrading process to refine surface finish.
It is rotates and reciprocate in the
3 It is either rotary or reciprocating
hole of work piece.
It is applied to get geometrical true
It’s applied to get high degree of
surfaces, correct minor surface
4 surface finish as well as to correct
imperfections and improve the
the roundness, taper in the work.
dimensional accuracy.
Abrasive particles are loaded on laps are
5 Honing stones are used as cutter.
used as a tool.
MRR in is 0.5 mm in primary and
6 MRR is 0 .005 mm to 0.01 mm
0.01 mm for secondary.
Used on internal and external
7 Mostly used on flat or regular surfaces.
cylindrical surfaces.