Gear manufacturing process nptel pdf

Singhmelkotecolton honing and superfinishing honing tool used to improve the surface finish of bored or ground holes. Most of the conventional miniature gears manufacturing processes produce miniature gears quality ranging between 9 and 12 din standard and require secondary finishing process to achieve the desired gear quality, i. Gear design national broach and machine division,of lear siegler, inc. Find materials for this course in the pages linked along the left. It is true shape generation process in that the gear shaped tool cuts itself into mesh with the gear blank. This shaving processcauses very fine chips are cut from the tooth surface process requires less than 1 minute. Gears can be manufactured by a variety of processes, including casting, forging, extrusion, powder metallurgy, and blanking.

Worm gear sets consists of a helical gear and a power screw worm, used to transfer motion between nonparallel and nonintersecting shafts. Design actual gear systems, including specifying materials, manufacturing accuracy, and other factors necessary for complete spur gear design. Roughing processes include milling the tooth shape. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses.

Metal casting processes indian institute of technology guwahati. A gear can be defined as a toothed wheel which, when meshed with another toothed wheel with similar configuration, will transmit rotation from one shaft to another. Hobbing process is carried out on gear hobbing machine using hob as tool. Continuous process improvement is a critical part of lean manufacturing. Manufacturing processes i nptel online videos, courses. Examples of parts made using shell molding include gears, valve bodies, bushings. You are grinding a steel, which has a specific grinding energy u of 35 wsmm3. Madsen manager, industrial products engineering, neenah foundry co.

Introduction to manufacturing processes introduction. Normally, either soft gear process dynamic or hard gear process dynamic is being aimed. The number of teeth for spur gears is given by where k 1f fll1 for fulld tht th08f tbt th d ldepth teeth, 0. It is therefore important to know the characteristics of the available engineering materials. Sparkerosionbased processes can achieve gear quality up to din. Forming consists of direct casting, molding, drawing, or extrusion of tooth forms in molten, powdered, or heat. Explain what a cam is, how it is used, and the typical types of cams. Gray cast iron nodular and ductile cast iron good casting property carburizing steel nitride steel bronze nonmetals as plastics, reinforced laminates noiseless operation, cheaper 4. Jan 01, 20 worm gear sets consists of a helical gear and a power screw worm, used to transfer motion between nonparallel and nonintersecting shafts. It is a very important manufacturing processes that can not only help the manufacturing process but can also improve product, its performance, and its characteristics in many ways. Metal casting is a labour intensive process automation.

Generally, process improvements are made regularly with new efficiencies embedded within the process. Pdf nontraditional manufacturing processes by gary f. Depending upon the type and accuracy of motion desired. Gear machining cnc machining is actually used in the manufacturing of gears with extreme precision and accuracy. This is a linear shaped gear which meshes with a helical gear.

Lecture 5 gear manufacturing nptel indian institute of. I the term am encompasses many technologies including subsets like 3d printing, rapid prototyping rp, direct. Unit 6 gear generation and finishing gear generation. Introductiona gear is an important machine elements which is used to for transmission of power or motion or both from one shaft to other. Now, if we look into the manufacturing process of processing then first of all the. Manufacturing technology gear shaping process gear shaping uses a cutting tool in the shape of a gear which is reciprocated axially across the gear blank to cut the teeth while the blank rotates around the shaper tool. Rajiv shivpuri professor of industrial, welding, and systems engineering, ohio state university. Master thesis erasmus mundus master of mechanical engineering setup of the manufacturing process and economic study of the gear box for industrial vehicle. From the beginning of the century, the demand for better productivity of gear manufacturing. Rack and pinion sets a special case of spur gears with the gear having an infinitely large diameter, the teeth are laid flat. Gear manufacturing processes gear transmission mechanics.

Instructional objectives i manufacturing process ii. Gear manufacturing methods engineering study materials. Setup of the manufacturing process and economic study of the. Gear machining is used to manufacture a number of products, including internal gears, worm gears, sprockets, spur and helical gears. Schematic illustrations of the superfinishing process for a cylindrical part. Introduction to gear, the various types of gear, gear terminology and gear manufacturing processes. Lecture notes design and manufacturing ii mechanical. Blodgett senior design consultant, lincoln electric co. Home tags manufacturing process hajra choudhary pdf download. Non traditional manufacturing processes an overview introduction nontraditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be. Gear technology septemberoctober 2006 the journal of gear manufacturing.

In this process a hollow broaching tool, called the pot, is used to cut the gear teeth. To meet the strenuous service conditions the gears should have. Module 3 selection of manufacturing processes nptel. Gear wheels shaving the gear and the cutter are run in mesh with their axes crossed at a small angle.

However with powder metallurgy process it is slowly getting into industry now for specific application. Machining is the manufacturing process by which parts can be produced to the desired. Oct 22, 2008 lecture series on manufacturing processes ii by prof. The double helical form balances the inherent thrust forces. Extra attention has been paid to the effects of friction and process planning in the result of process loads and also on the gear quality. Production processes of gear rack is a page to introduce production process of gear rack done in khk facotory. Length wise gashes or flutes are cut across the spiral to form cutting edges 37. Gear manufacturing can be divided into two categories namely forming and machining as shown in flow chart. M arc on pitch circle from flank of one tooth to other tooth. Definitions diametral pitch, p nd module m is reciprocal of p dn circular pitch. The production process required for gear manufacturing covers a lot of ground, but general examples which can be given include cutting of materials with cutting machines, processing of materials with lathes, cutting of cylindrical gear teeth with hobbing machines, cutting of rack teeth with rack panels, cutting of internal gear teeth with gear. Solutions being sought are not corrective but preventative.

Classification of manufacturing processes for producing of products materials are needed. However, manufacturing considerations limit the profiles to simple curves belonging to the circle group, or those which can be readily generated or f. Gear technology marchapril 2004 35 gear heat treatment. It includes detailed information to gain insight into the manufacturing processes which are new, unconventional and list out the the. To understand the gear manufacturing or gear cutting process it is necessary to understand gear. Gear manufacturing process dynamics are undergoing a major breakthrough in last two decades. The grinding wheel rotates at 3600 rpm, has a diameter d of 150 mm, thickness b of 25 mm, and c 5 grains per mm2. Download the seminar report for gear manufacturing processes. Automobiles, gear boxes, oil engines, machine tools, industrial machinery, agricultural machinery, geared motors etc. Gear manufacturing lecture by allan arch at fiu mechanical engineering, miami, florida duration. Also, the cutter and the gear blank both are rotated slowly about their own axis. Specifically, hobbing, milling, and shaping are defined, as well as the four primary types.

Jul 25, 2015 manufacturing technology gear shaping process gear shaping uses a cutting tool in the shape of a gear which is reciprocated axially across the gear blank to cut the teeth while the blank rotates around the shaper tool. Lecture series on manufacturing processes i by prof. The second graph plotted is the range of thickness is plotted. Download nontraditional manufacturing processes by gary f. Hypoid gear this is a deviation from a bevel gear that originated as a special development for the automobile industry. During the rotation the gear is reciprocated longitudinally across the cutter. Lecture 5 gear manufacturing contents of the lecture gear manufacture can be divided into two categories, forming and machining. Manufacturing of gears is a very interesting area involving various methodologies and varies with the type of gears to be produced. Non traditional manufacturing processes an overview. Gear technology, the journal of gear manufacturing issn 07436858 is published bimonthly by randall publishing, inc. Broaching is a machining process for removal of a layer of material of desired width and depth. Broaching is a machining process that uses a toothed tool, called a broach, to remove material. A material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. Nptel course on manufacturing processes i, pradeep kumar et al.

Miller welding design engineer, lincoln electric co. Lecture series on manufacturing processes ii by prof. This process is usually done by an experienced machinist. Gear cutting me 312 manufacturing technologyvikrant sharma, mechanical engineering department. As a general rule, however, machining is applied to achieve the final dimensions, shape and surface finish in the gear. Determine allowable force on gear teeth, including the factors necessary due to angle of involute of tooth shape and materials selected for gears. Gears play a prominent role in the mechanical power transmission. Different gear combinations are used to give the smooth running, the lower fuel consumption, and the optimum driving comfort. Box 1426, elk grove village, il 60007, 847 4376604. Gears are used extensively for transmission of power. Gear manufacturing an overview sciencedirect topics.

Process equipment tends to be more complex thus problems can be more complex designing a product wheel for a process making sheet goods of various widths, thicknesses, tensile strengths, and densities is more complex than developing a mixedmodel schedule for a process making gear pumps. Gear manufacturing has been one of the most complicated of the metal cutting processes. Hob is a cylinder on the surface of which a continuous thread has been cut having the cross section of involutes gear teeth. Milling is a basic machining process which uses the relative motion between a rotating, multiedge cutter and a workpiece to cut individual gear teeth. The smallest number of teeth on a spur pinion and gear, onetoone gear ratio, which can exist without interference is np. Lecture 26 broaching principle systems and applications. Gear generation and unit 6 gear generation and finishing finishing operations operations structure 6. Connecting rods manufacturing improvements and process planning tolerance chain analysis and training material silvia garde gonzalez master thesis 2015 kth royal institute of technology. The thesis structure is based on four published papers, and some additional results from. The bulk of power transmitting metal gears of machinery are produced by machining process from cast, forged, or hot rolled blanks. This process is the most versatile of all gear cutting processes.

In this process, a pinion shaped cutter is used, which is mounted with its axis vertical and is reciprocate up and down. Unit 6 gear generation and finishing gear generation and. Part of the fundamental manufacturing processes video series, this program introduces many primary gear terms and definitions, including involute curve, base. Gear manufacturing processes free download as pdf file. Generally, passenger car transmissions are provided with 45 forward speeds and one reverse speed. Double helical gear this is a gear with both lefthand and righthand helical teeth. Norton, design of machinery introduction to cam design. Gear manufacturing methods engineering study materials, gear manufacturing methods, gear manufacturing process in hindi, gear manufacturing process pdf, gear manufacturing process nptel, gear. Mechanical engineering manufacturing processes ii nptel. Classification of manufacturing processes engineers gallery. Periodical postage paid at arlington heights, il, and at additional mailing office usps no. Gear design national broach and machine division,of.

In linear broaching, which is the more common process, the broach is run linearly against a surface of the workpiece to effect the cut. Again, it can be regarded as a portion of a helical gear with infinite radius. This article describes the various methods of manufacturing methodologies followed for each type of gear. Additive manufacturing i additive manufacturing am refers to a process by which digital 3d design data is used to build up a component in layers by depositing material. The influence of materials and geometry types of gears gears play an essential role in the performance of the prod. A poorly designed process results in overuse of manufacturing resources men and machines. Forming consists of direct casting, molding, drawing, or extrusion of tooth forms in molten, powdered. Jun 12, 2018 gear manufacturing methods engineering study materials,gear manufacturing methods,gear manufacturing process in hindi,gear manufacturing process pdf,gear manufacturing process nptel,gear.

Classification of metal removal processes and machine tools. A gear box transmits the engine power to the driving wheels with the help of different gearing systems. One important application of form milling is in gear manufacturing. Iron is good because of its castability and wear characteristics. What are the sources of errors in gears and measurement of. Paul,department of mechanical engineering, iit kharagpur. If the mating gear has more teeth than the pinion, that is.

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