Program: Diploma (Mechanical

Engineering ) Class: TYME

Semester : V
Course: Advanced
Manufacturing Processes
Course code : 22563
Unit No./:-03 GEAR
MANUFACTURING
 Presented By 02

Name of the Trainer : Prof. Sandeep K.Aher (M.E.Design),

Years of Experience : 08 years
Domain Expertise : Mechanical Engineering

Department Of Mechanical Engineering,Sandip Polytechnic,Nashik

www.sandipuniversity.edu.in https://www.sandipfoundation.org/
Program Name : Diploma in Mechanical Engg.
Course : Advanced Manufacturing Processes(AMP-22563)
Unit No.03:-GEAR MANUFACTURING (10Marks)

Presented By:
Prof. Sandeep K. Aher {M.E. Design}

Course Outcomes(COs) :
At the end of the course, student should able to
CO1: Choose relevant machining process to produce gears.
CO2: Explain the procedure of given gear manufacturing & finishing Process.
CO3: Draw sketch of given gear Hob,hobbing process or gear shaping process.

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Course : Advanced Manufacturing Processes(AMP-22563)
Unit No.03:- GEAR MANUFACTURING (10Marks)
Topics and Subtopics
3.1 Gear Manufacturing Methods: Function and Types of Gears, Gear Manufacturing
Methods
3.2 Gear Hobbing: Working Principle, Types of Gear Hobbing, Advantages, limitations &
Applications of Gear Hobbing
3.3 Gear Shaping: By Pinion Cutter, Gear Shaping by Rack Cutter, Advantages,Limitations &
Applications of both the Methods & Comparison of Gear Hobbing & Gear Shaping
3.4 Gear Finishing Methods: Need of Gear Finishing, Gear Finishing Methods:
(a) Gear Shaving (b) Gear Grinding
(c) Gear Burnishing (d) Gear Lapping
(e) Gear Honing
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1. INTRODUCTION TO GEAR CUTTING:-

• Gear is one of the important machine tool elements which is an integral and
inevitable part of power transmission system.
• A gear is a round blank having teeth along its periphery. A gear is defined as a
toothed wheel which when meshed with other gears transmits motion from
one part of mechanism to another.
• Gears transmit power or torque as well as rotary motion from one shaft to
another. Along with the transmission of power gears also transfer the accurate
velocity ratio between two shafts.
• Gears may be internal as well as external. Gears are vastly used to form
mechanism for transferring power from prime mover to the place where other
parts in the machine is to effect change in speed, torque or both.
• Speeds of two different parts in a machine can also be maintained relatively
and precisely.

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FUNCTIONS OF GEAR:-
1.The gear performs the following functions:
2. To transmit torque from the driving
shaft to driven shaft.
3. To reduce the speed generated
by prime mover.
4. To change the direction of rotation
through idlers

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Classification:-
• The gears are classified as follows.
• 1. According to the position of axes of shafts
(a) Shaft axes Parallel
• Spur Gears
• Helical Gears
• Herringbone Gears
• Rack and Pinion
(b) Shaft axes Intersecting
• Straight Bevel Gears
• Spiral Bevel Gears
(c) Shaft axes non-intersecting and non-parallel
• Hypoid Gears
• Worm gears
• Screw gears
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Classification- Cont….
2. According to the peripheral velocity of the gears
(a) Low-velocity gears
(b) Medium velocity gears
(c) High-velocity gears
3. According to the type of gears
(a) External gearing
(b) Internal gearing
(c) Rack and pinion
4. According to the position of teeth on the gear surface
(a) Straight gear
(b) Inclined gear

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TYPES OF GEAR:-
3.1 Spur Gears :-

•This is a cylindrical shaped gear in which the teeth are parallel to the axis. It has the largest
applications and, also, it is the easiest to manufacture.
•Spur gears have teeth parallel to the axis of rotation and are used to transmit motion from one
shaft to another, shaft.
•These gears are the simplest form of gears having cylindrical shape.
•They are easy to manufacture, have less cost and have highest efficiency.
•They are used in high speed and high load application.

Fig. 3.1 Spur Gear

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3.2 Helical Gears:-
1.Helical gears have teeth that ore oriented at an angle to the shaft.
2. This causes more than one tooth to be in contact during operation.
3. Helical gears are capable of carrying more load than spun gears.
4. Due to the load sharing between teeth this arrangement also allows helical gears to
operate smoother and quieter than spur gears.
5. They can transmit higher loads, making them suitable for high speed applications.

Fig.3.2 Helical gear

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3.3 Herringbone Gears

1.Herringbone gears are also known as Double Helical Gears.
Herringbone gears are made of two helical gears with opposite helix angles, which can be up
to 45 degrees.
2. A top view of double helical gear looks like V letter.
3. These have zero axial thrust which is not so with the single helical gear.
4. Unlike helical gears it has advantage of transmitting power smoothly because it meshes two
teeth at time.
5. They are ideally suited for high shock and Vibration applications.
6. Herringbone gearing is not used very often due to their manufacturing difficulties and high
cost.

Fig.3.3 Herringbone Gear

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3.4 Rack and Pinion
1. Rack is a linear shaped gear which can mesh with a spur gear often called as pinion.
2. The pinion can have any number of teeth but should have the same module as that of the
rack.
3. The rack is a portion of a spur gear of infinite radius it converts rotary motion into a linear
motion.
4. It is used in spindle of drill machine
Pinion

Rack
Fig. 3.4: Rack and Pinion

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3.5 Straight Bevel Gears:-

1. Bevel gears are conical in shape having teeth formed on the surface.
2. This is a gear in which the teeth have tapered conical elements that have the same
direction as the pitch cone base line.
3. The straight bevel gear is widely used as it is easy to manufacture in a bevel gear
family.
4. Miter gear is a special form of bevel gears where the shaft intersects at 90 degree
and the ratio is 1:1

Fig. 3.5: Straight Bevel Gears

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 3.6 Spiral Bevel Gears:-
1. This is a bevel gear with a helical angle of spiral teeth.
2. It is much more complex to manufacture, but offers a higher strength and lower
noise.
3. Spiral bevel gear has advantage over straight bevel gear for gear strength, Oscillation
and noise level.
4. Disadvantage of Spiral bevel gear is axial thrust load. Therefore proper bearing
location and firm support are needed.

Fig. 3.6: Spiral Bevel Gears

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3.7 Hypoid Gears:-

1. This gear is similar to spiral bevel gear. This gear is used for power transmission between non
parallel and non-intersecting axis of conical gear.
2. These gears are also used for right angle drive which permits the lowering of the pinion axis
which is an added advantage in automobile.
3. However the non-intersection introduces a considerable amount of sliding and the drive
requires good lubrication to reduce the friction and wear.
4. Their efficiency is lower than the other two types of bevel gears.
5. These gears are widely used in current day automobile driveline power transmission.

Fig. 3.7: Hypoid Gears

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3.8 Worm Gears:-
1.Worm gear consists of a meshed worm and worm gear.
2. The worm resembles a screw thread and the mating worm gear (a helical gear).
3. The outstanding feature is that the worm offers a very large gear ratio in a single mesh.
4. However, transmission efficiency is very poor due to a great amount of sliding as the worm
tooth engages with its mating worm gear tooth and forces rotation by pushing and sliding.
5. In these gears, the engagement occurs without any shock. The sliding action in the system
results in quieter operation.

Worm
Fig. 3.8: Worm Gears
Worm Gear

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ADVANTAGES OF GEAR DRIVES

1. Can transmit more power than other type of drive.
2. Transmission efficiency is high.
3. It requires less space
4. Maintenance is easy
5. They have zero slip.
6. They have good durability and precision
DISADVANTAGES OF GEAR DRIVES
1. Gear design and manufacturing is expensive
2. Installation is difficult.
3. Tooth wear may occur during power transmission
4.Inaccuracies in gear tooth cause noise and vibrations.

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GEAR MATERIALS:-
•The material used for the manufacture of gears depends upon the strength, Easy of
manufacture, service conditions (like wear, noise, temperature, vibration etc), Overall cost of
material and manufacture.
The materials generally used for making gears are
(a) Metallic materials:- Ferrous metals for high loads:
•Cast Iron is used when large gears are to be produced and when stresses are not high
•Medium and high carbon steels are extensively used in Industrial gears
•Alloy steel is used when low tooth wear is required.
Non-ferrous metals for light load:
•Aluminium is used for lightweight gears, gears in toys, instruments.
•Bronze is used in order to reduce wear.
(b) Non-metallic materials
•Non-metallic gears are widely used for light load, non-precision and noiseless operation.
•Wood, plastic or fiber are used as non metallic material.
•Such gears cannot be used to transmit heavy power.

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SELECTION OF GEAR MATERIALS:-

•The proper selection of gear material depends on:-

•Amount of power to be transmitted
•Size and weight of the gear
•Service period of the gear
•Continuous or intermittent mode of drive
•Method of manufacture to be used
•Service requirement - noiseless drive, light/heavy drive
•Degree of accuracy required.

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GEAR MANUFACTURING METHOD:-

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SELECTION OF GEAR MANUFACTURING METHOD:-

•Machining or gear cutting is the most common and accurate method of gear manufacturing
•The Type of Gear Manufacturing Method depends on:
•Type of gear
•Size of gear
•Quantity required
•Accuracy desired
•Cost and availability of equipment.

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 GEAR CUTTING ON MILLING MACHINE:-
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•On milling machine, the gear cutting operation is performed by using formed milling cutter.
Gear form milling cutter may be used for this purpose.
•The cutter profile corresponds exactly with the tooth space of the gear.
•The cutter is mounted on arbor of the milling machine. The gear blank is mounted on
dividing head spindle.
•Feed mechanism is then engaged to make the blank to traverse past the cutter.
•Then blank is withdrawn and indexing is done by the universal dividing head so that next
tooth space can be cut.
•This forms one tooth and the process is repeated till all the teeth are formed.

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 GEAR HOBBING:-
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1. Gear hobbing is a process of generating gear teeth by means of a rotating cutter

known a ‘Hob' that revolves and cuts like a milling cutter.
2. The hob is similar to worm equipped with proper clearance for cutting action
3. Flutes are cut across the threads forming racked shaped cutting teeth.
4. The thread (start) may be left or right handed and flutes may be straight or
helical.
5. A hob may have one, two or more threads. Single threaded hob cuts one teeth
and double threaded hob cuts two teeth simultaneously.
6. The number of teeth depends on the ratio of the revolutions of hob to
revolutions of gear blank.
7. Hobs are made with any desired pitch and can be used to manufacture the gear
of that pitch.
8. Any number of teeth can be cut on gear blank. It is continuous process

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Principle of Operation:-
Gear hobbing is a machining process in which gear teeth are progressively generated by a
series of cuts with a helical cutting tool (hob).

Fig. Set-up of Gear Hobbing

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Hobbing Process:-
•The process of hobbing is shown in Fig.
•In this process the hob and gear blank are mounted on the shafts that are at right angles to
each other. The hob axis may be either horizontal or vertical.
•For machining of spur gears, the hob must be titted through its helix angle to result in the
involute profile.
•The hob and blank are rotated about their axes with different speeds.
•The blank is then moved towards the hob until proper depth is reached.
•The hob is then fed into the gear blank.

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•As soon as the proper depth is achieved, the hob is fed in a direction parallel to the axis of
rotation of the gear blank.
•This enables the teeth to be gradually cut over the full face of the gear blank.
•Both the hob and blank are rotated as if they are in mesh with each other.
•The speeds of two are so adjusted that the blank rotates through one pitch distance for
each complete revolution of the hob.
•This results in generation of teeth on the blank periphery. The operation is a continuous
one with no break in between.
•Thus the gear cutting with hob involves three basic motions, all of them occurring at the
same time:
•The rotation of hob.
•The rotation of blank
•The axial advancement (feed) of the hob.

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Advantages of Gear Hobbing
1. It is faster and continuous process.
2. Rate of production is high as it cuts several teeth simultaneously
3. High accuracy can be obtained
4. Many gears of same size can be cut simultaneously
5. It can cut spur gear, helical gear worm gear, sprockets, splines etc.
6. Gap type herringbone gears can be generated only through this process
7. Long shafts and splines can be easily accommodated on hobbing machine.
8. Irrespective of number of teeth, same hob can be used for same module of gear
Limitations of Gear Hobbing
1. It cannot generate internal gears.
2. It cannot cut the gears which are having shoulders and flanges.
3. It cannot produce asymmetrical shapes.
Application:-It is used to produce spur gears, helical gears and worm and worm wheels

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GEAR SHAPING:
Gear shaping is a gear generating process. It is adopted because of its high speed and versatility.
Gear shaping process is of two types:
1. Pinion cutter generating process
2. Rack cutter generating process

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Principle:-
•The cutter is mounted with its axis vertical and is reciprocated up and down by sliding
the spindle head along vertical ways of machine.
•In addition to reciprocating motion, the cutter and gear blank both are rotated slowly
about their own axis.
•Relative speed of rotation of the two is the same as the gear to be cut.
The principle motions involved in rotary gear shaper cutting are:
1. Cutting stroke: The downward linear motion of the cutter spindle together
with the cutter.
2. Return stroke: Upward linear travel of the spindle and cutter to withdraw
the later to its starting position.
3. Indexing motion: Against each rotation of cutter the gear blank revolves
through revolutions, where n number of teeth on cutter, N = number of teeth
to be cut on gear blank

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Pinion Cutter Gear Shaping Process:-
•In this method instead of rack cutter a pinion cutter having formed similar to gear to be
produced is used.
•The pinion cutter reciprocates along vertical plane. Gear blank is mounted on a vertical
shaft and rotates very slowly.

Fig. Pinion Cutter Gear Shaping Process

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Cont...
•The depth of cut is given during the cutting stroke (Downward stroke) and during return
stroke work is reviewed and cleared from cutter.
•During the process the cutter is fed radially to the gear blank to obtain required tooth depth.
•The use of pinion makes the process continuous and rate of production is more.

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Pinion Cutter Gear Shaping Process:-

•In this method instead of rack cutter a pinion cutter having formed similar to gear to be
produced is used.
•The pinion cutter reciprocates along vertical plane. Gear blank is mounted on a vertical
shaft and rotates very slowly.

Fig. Pinion Cutter Gear Shaping Process

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Rack Cutter Gear Shaping Process:-

•In this method, the cutter has a rack form for the gear to be generated.
•The gear blank is rotated slowly and uniformly about the vertical axis.
•The rack cutter reciprocates with the required cutting speed to remove the material from the
gear blank.

Fig. Rack Cutter Gear Shaping Process

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 Cont...
•The cutter is radically fed to obtain the correct teeth depth by
means of cam.
•The cutter removes the material only during cutting stroke and
relieved during return stroke.
•Thus because of reciprocating motion of cutter and angular relative
motion of gear blank, gear teeth is generated on the gear blank.
•The main limitation of this method is that once the full length of
rack is utilized the operation is required to be stopped.
•In such case the blank is indexed next and the cut started as usual.

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Advantages of Gear Shaping

1. It is fast process suitable for medium and large size batch production.
2. Most of the gears like spur gears, racks, double helical gears, herringbone
gears, sprockets can be generated by this process.
3. Teeth very close to shoulder can also be cut.
4. Gears cut have good profile.
5. For same pitch same cutter can be used.
6. Both external as well as internal gears can be cut (for pinion cutter process).
Limitations of Gear Shaping
1.For cutting helical gears special guide called as helical guide is required.
2.Worm and worm wheels cannot be produced by this met.
3. Cutting takes place only in forward stroke (for rack planning) and return stroke is
idle, so time is wasted

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COMPARISON BETWEEN HOBBING AND
SHAPING PROCESS
Sr.No Features Hobbing Shaping
Better with respect to tooth Better with respect to tooth
1 Accuracy spacing and runout. Equal so far form.
lead accuracy is required.
Hobbing produces a series of Shaping produces a series of
Surface radial hats based on feed rate straight Lines parallel to the axis
2
finish of hob across the work of the gear. Surface finish may be
better.
Cannot be used for internal Can be used for internal gears
3 Versatility
gears
Faster for gears with larger face Time cycle will be 2-3 times of
4 Limitation
width. hobbing for wider gears.
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NEED OF GEAR FINISHING:-

Gear finishing is done with the following purposes.
1. For smooth running, good performance and long service life, the gears need
2. To achieve be accurate in dimensions and forms
3. To achieve high surface finish.
4. To be hard and wear resistive at their tooth flanks.
5. To remove inaccuracies produced through gear generating process.
Gear teeth finishing work after near accurate performing and machining can be achieved by
finishing processes.
Gear finishing is a process of removing or clearing out the irregularities from the blank of the
gear, where the teeth came in contact with each other during machinery.

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GEAR FINISHING PROCESSES:-

The surface of gear teeth produced through gear generating process is not very
accurate and properly finished. Such surface results in lot of noise, excessive wear,
play or backlash while meshing teeth or sometimes may cause ultimate failure.
The commonly used finishing operations are-
•Gear shaving.
•Gear grinding
•Gear burnishing.
•Gear lapping.
•Gear honing.
•Roll finishing.

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GEAR SHAVING-

(a) Cast Iron cutter (b) Enlarged view of tooth showing (c) Gear shaving cutter
serrations
• In gear shaving process, very thin chips are removed from the gear tooth surface by the
cutting edge of gear shaving cutter.
• Gear Shaving is employed to remove the material on the teeth in the form of very fine
chips of sizes 0.005 mm to 0.1 mm from the gear tooth.
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Cont...
• The cutter has narrow grooves or serrations on the tooth flanks. These teeth form the
cut edges of the shaving cutter.
• It is process of finishing gear teeth by running the gear at high speed in mesh with
shaving tool, which is in the form of rack or pinion.
• The teeth of shaving tool are hardened, accurately ground and their faces are
provided serrations.
• These serrations form the cutting edges which actually provide a scraping operation
on mating faces of gear teeth to be finished.
• The gear is pressed in contact with rotating shaving tool. The gear rotates in mesh
with shaving tool and is also reciprocated simultaneously.
• This prevents Jamming of two and relative motion between shaving tool and gear
results in high surface finish on gear.

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 GEAR GRINDING
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•Gear operating at high speeds and high loads are always hardened and there is distortion
gear flank.
•In order to remove this distortion and to have accurate profile on gear teeth, for smooth
running gear grinding is done.
•Grinding is a very accurate method and is, though relatively expensive, more widely used for
finishing teeth of different type and size of gears of hard material or hardened surfaces.
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•The properly formed and dressed wheel finishes the gear teeth flanks by fine
machining or abrading action of the fine abrasives.
•The grinding tool is formed by trueing the grinding wheel to the shaped and size
of gear tooth to be finished.
•The gear is mounted on Indexed head and grinding wheel is fed to required
depth. The gear is then withdrawn and indexed for next teeth.

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 GEAR BURNISHING:- 43

•Gear burnishing is the cold finishing process of gear teeth and used for gears after
cutting but before hardening to improve the surface finish and uniformity
•The gear is mounted on a vertical reciprocating shaft in mesh with three hardened and
ground burnishing gears.
•These gears are power driven and are fed into the cut gear and rotated through a few
turns in both directions.
•This makes the gear surface smooth and also imparts little hardness on it.
•The load is provided by means of pneumatic, hydraulic or electric means.

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 GEAR LAPPING:- 44

•The gears which are finish machined or shaved and then heat treated and finally lapped
to remove scale, improve Surface finish on teeth and rectify small errors due to
distortion during the hardening process.
•In this process, the gears to be lapped are run under load in mesh with one or more cast
iron toothed laps.
•Either abrasive paste is introduced between the teeth or fine abrasive powder, mixed in
oil and is made to flow through the teeth during running.
•A negligible amount of metal is removed during this process.
•Gear lapping helps in improving surface finish.

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GEAR HONING:-
•It is a gear finishing process for hardened gears. It improves the surface finish of the
tooth profile. It also reduces the noise of spur and helical gears after heat treatment
and corrects heat treatment errors.
•Gear tooth honing is generally carried out with a constant pressure between teeth of
the gear and honing tool.
•On a machine tool resembling the gear shaving machine, gear honing is performed.
Gear tooth hone is an abrasive imbedded plastic helical gear shaped tool.
•The grain size of the abrasive is selected
between 0.025 to 0.05 mm which is
suitable for the honing allowances
as well as requirements of surface finish.

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