Unit 6:

Gear Cutting Processes

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 Introduction
What is Gear?
A gear is a toothed cylindrical or roller shape component of a machine which meshes with
another toothed cylindrical to transmit power from one shaft to another. It is mainly used to
obtain different torque and speed ratio or changing the direction of driving shaft and driven
shaft.
There are many other power transmission devices like belt drive, chain drive, rope drive etc.
but the main advantage of gear system has almost negligible or no slippage between driving
and driven member. Ttis mainly use where, there is short distance between axis driving and
driven shaft like bicycle motorcycle, car etc
Principle:
It works on the basic principle of thermodynamic which state that energy is neither be
created or destroyed or we can say it is conservative. it can be converted into one form to
another. We know that power is the function of speed and torque or we can say that power
is product of torque (Force in rotary motion) and speed (P = TV) of the shaft. So when we
connect a small gear on driving shaft and a larger gear on driven shaft, the speed decreases
of driven shaft per unit rotation of driving shaft.
Because the power is conservative so according to this the torque of driven shaft increase
according to the ratio of driving gear to driven gear or according to ratio of driving velocity
to driven velocity. So by use of various sizes of gears we can obtain many combination of
torque and speed of driven member.
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 Introduction
Types of Gears:
Gears can be classified in various types according to construction of teeth, Use, the
direction of motion transfer etc. but basically it is classified according to design of teeth.
Today we will describe most important types of it.

1. Spur Gear:
• These gears are used to transmit the power in
same plane or when the driving and driven
shafts are parallel to each other.
• In this type of gear teeth are cut parallel to the
axis of the shafts so when is meshes with
another spur gear it transmit the power in
parallel shaft and when it connects with the
helical gear it will transmit power at an angle
from the driving axis.

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 Introduction
Types of Gears:

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 Introduction
Types of Gears:

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Introduction

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Introduction

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Introduction

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Introduction

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Introduction

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Introduction

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Introduction

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 Introduction
Methods of Gear Forming
Gears can be manufactured by a variety of processes, including casting, forging,
extrusion, powder metallurgy, and blanking. Of these, machining is the most
common manufacturing method used.
Gear machining is further classified into two categories: gear generating and gear
form-cutting.

1. Gear Generating Method

Most cut gears produced in big
numbers are made on machines
that utilize the gear-generating
method. This method involves
gear cutting through the relative
motion of a rotating cutting tool
and the generating, or rotational,
motion of the workpiece. The two
primary generating processes are
hobbing and shaping.

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 Introduction
Methods of Gear Forming
2. Gear form-cutting
Uses formed cutting tools that have the actual shape, or profile, desired in the
finished gear. The two primary form-cutting methods are broaching and milling
Broaching is the fastest method of machining gears and is performed using a
multi-tooth cutting tool called a broach.
Each tooth on the broach is generally higher than the preceding tooth.
As a result, the depth of cut increases
with each tooth as the broaching
operation progresses.
Broaching is typically used to produce
internal gear teeth.
External teeth can be broached using “pot
broaching”. In this process a hollow
broaching tool, called the pot, is used to
cut the gear teeth.

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 Introduction
Methods of Gear Forming

3. Gear finishing
After gears have been manufactured, they require a number of
finishing operations. which include heat treatment and final
dimensional and surface finishing. This finishing can be
accomplished using:
Shaving – Shaving is performed with a cutter having the exact
shape of the finished gear tooth. Only small amounts of material
are removed by a rolling and reciprocating action. The process is
fast but generally expensive due to the cost of machinery and
tooling. Shaving is typically performed prior to heat treatment.
Grinding – Grinding sometimes serves as an initial gear production
process, but is most often employed for gear finishing. Grinding is
classified as either form grinding or involute-generation grinding.
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 Introduction
Gear Shaping

• Gear shaping is a technique for creating teeth on the gear by

using a gear shape cutter.
• In gear shaping operation, the gear shape cutter is used which
possess cutting edges on the gear.
• The gear shape cutter as well as the workpiece (gear blank)
rotates as if they are actually meshing with each other.
• Due to the rotation of gear shape cutter, the cutting action
takes place on the workpiece by a series of incremental cuts.
And finally the desired tooth profile is obtained.

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 Gear Shaping Process

In gear shaping operation,

the gear shaped cutter
having cutting edges is
used which has a
clearance on the tooth
face and sides.
This gear shape cutter
has a hole in the centre
which is required to mount
it on a spindle of the
machine.

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 Gear Shaping Process
• As shown in the diagram, the cutter is mounted on a vertical axis and it moves up
and down.
• Apart from the up-down reciprocating movement, the rotation of the cutter and
workpiece also takes place during this movement
• The relative speed of cutter and the workpiece is the same because the cutter and
workpiece will have the same size and the same number of teeths.
• There are change gears attached with the gear shaper which helps in achieving the
same rotation speed for cutter and workpiece.
• Thus the rotational movement and liner movement (up to down) of the spindle
generates teeth on the workpiece.
• But besides this, the feed is also given to the workpiece or cutter to achieve the
cutting of the teeth

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 Gear Shaping Process (by gear hobbing)
• The rotary gear shaper cutting involves various motions that are
mentioned below.

The cutting of heat tooth takes place

either in an upward stroke or downward
stroke of the cutter.
During the return stroke, either the cutter
is withdrawn from the table or the table is
withdrawn from the cutter.
This is done to prevent the rubbing of
cutting edges to prevent its wear as well
as to protect the damage of tooth profile
of workpiece.
By using gear shapers, the straight tooth
as well as helical tooth can be cut on a
gear blank.

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 Gear Shaping Process (by rack type cutter)
• In order to cut the helical tooth, the tool and the gear blank should be
rotated in an oscillating rotational motion.
• Gear shaping also uses rack type
cutters or rack shaped cutters.
• In this method, the rack type cutter
reciprocates in the horizontal and
vertical direction and the workpiece
(gear blank) meshes with it, which
forms a rotational motion.
• During this the cutting action takes
place on the workpiece.
• The main disadvantage of using a rack
type cutter is that once the full length
of the rack is used, the cutting
operation is required to be stopped to
bring the workpiece back to the
position. (This is mostly done when
cutting larger gears with more teeth.) 20
 Gear Shaping Process
Gears manufactured by gear shaping are used in areas like;
Automobiles, Machine tools, Instruments, Machinery, Clocks, And many other
equipment.

The advantages of gear shaping are mentioned below.

•Gear shaping is a fast gear cutting technique and it is suitable for medium as well as
large size production of gears.
•The chips of uniform size are cut by the gear shape cutter. Hence this method shows
high dimensional accuracy.
•Sour gear, helical gear, cluster gears, splines, and many other gears can be cut by gear
shaper.

The disadvantages of gear shaping are mentioned below.

•It is difficult to cut gears having wider flanks, because the length of the cut is
shorter.
•Different helical guides are required to cut helical gears with different helical angles.
•By this method, only one gear can be cut at a time.

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 Gear Milling by a Formed Disc Cutter
• With form cutting, the cutting edges on the milling tool have the shape of the
tooth space.
• The milling tool mills each tooth space individually before the gear blank is
rotated one tooth space at a time.
• The teeth of the gear are produced exclusively by the rotational motion of the
tool.
• During the machining process, there is therefore no superimposed rotational
motion of the gear blank as is the case with gear hobbing, shaping or planing.
• In the latter three manufacturing processes, the shape of the tooth is created by
the envelope of the cutting edges; with form cutting or broaching , however, the
tooth shape is created directly by the cutting edge geometry of the tool.
• In contrast to hobbing, shaping or planing, the cutting motion of the tool does
not have to be matched to the motion of the workpiece.
• Therefore, form cutting can also be carried out on ordinary milling machines.
However, since the tooth spaces have different geometries depending on the size
of the gear, a single form cutter can only be used to produce a specific gear.
• For each module (or diametral pitch) and each number of teeth, separate disc
cutters are required, which are relatively expensive due to the individual shape.
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Gear Milling by a Formed Disc Cutter

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Thank You

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