Gear Making
Gear Making
Gear Making
A Presentation by S.Krishnamorthy, IRSME (Retd) For Polytechnic College students of Tamil Nadu
[email protected]
Unit - IV
Involute tooth
Involute
Involute
Steering Gear
Rack Railway
Escapement in a clock
Balance Stop
Mechanical Clock
Forming Gears
Single point cutting tool Multipoint cutting tool Simple and cheaper Less accurate Can be done in shaper, slotter, broaching or milling machines Formed disc cutter to the shape of space between teeth
Forming Gears
Dividing Head
Dividing heads are used for:
Holding and Indexing the workpiece (gear blank)
Indexing is the process of dividing the periphery of the workpiece into any number of equal divisions.
1-index plate; 2-index crank; 3-spindle; 4-worm wheel (z=40); 5-necks to receive pick-off gears; 6-worm (k=1); 7-sector arm.
Dividing Head
Methods of Indexing
Direct or Rapid Indexing Plain or Simple Indexing Differential Indexing Angular Indexing
Direct Indexing
Direct Indexing (Rapid Indexing) is the simplest form of indexing. Used for quick indexing of workpiece. The direct indexing plate is mounted on the nose of the dividing head spindle which also carries the work. The number of divisions required by direct indexing is limited by the number of holes/slots in the direct indexing plate. Direct indexing plates are available with 24, 30 and 36 holes or slots. It is possible to index any number of divisions which is a factor of total holes/slots in the plate
Direct Indexing
Whenever starting to machine the first hole, it is necessary to make sure that the indexing pin is in the hole or slot No. Zero or 24 of the indexing plate. After doing the necessary indexing movement, it is required to clamp the indexing spindle so that the cutting force will not go onto the indexing plate and indexing pin.
Simple Indexing
40 turns of indexing crank = 1 revolution of index head spindle Index plates with concentric circles of holes:
Plate: 1 - 15, 16, 17, 18, 19, 20 Plate: 2 - 21, 23, 27, 29, 31, 33 Plate: 3 37, 39, 41, 43, 47, 49
For cutting 30 teeth, 40/30 = 1 + 1/3 = 1 + 7/21 (One complete turn of indexing crank and 7 holes in 21 hole circle of the index plate)
Differential Indexing
This method is used for divisions that could not be indexed by simple indexing The required division is obtained by combination of:
Movement of the index crank similar to simple indexing Simultaneous movement of the index plate when the crank is turned
The rotation of the index plate may be in the same direction or opposite to the crank rotation
Differential Indexing
Lock pin is disengaged to permit rotation of index plate A sleeve with bevel gear is connected to the index plate The sleeve and the bevel gear are free to rotate on the worm shaft
Another bevel gear engages with it and the shaft of that gear has change gears that mesh with the gear mounted on the back of the main spindle Crank rotates the spindle Spindles motion is transmitted to index plate through change gears
(A-N) X 40/A
where: N = The required number of divisions to be indexed A = a number nearer to N which can be indexed by plain indexing (assumed number)
With these gears and the three sets of standard index plates, it is possible to index any number from 1 to 382.
Selection of gears
Angular Indexing
Angular indexing is the process of dividing the periphery of a work in angular measurements and not by the number of divisions. Indexing method is similar to plain indexing One complete turn of crank will cause the spindle and the work to rotate through 360/40 = 9 Index crank movement =
Angular displacement in deg/9 Angular displacement in minutes/540 Angular displacement in seconds/32400
Linear Indexing
Linear indexing is used for moving the work table to the required distance lengthwise during rack milling It is the method of dividing the linear distance into number of equal divisions When the crank is rotated, the table is moved longitudinally through a gear train
Line of Action
Two involute gears, the left driving the right Blue arrows show the contact forces between them. The force line (or Line of Action) runs along a tangent common to both base circles.
Involute curve
3. 4. 5. 6. 7. 8. 9. 10.
Dedendum Working depth Tooth depth Outside diameter Tooth thickness Clearance Circular pitch Radius of fillet
Feed: normal 7. Mounting and centering the cutter: Aligning centre of cutter with centre of
tailstock
1. 2. 3.
4. 5. 6.
Helix Angle
Helix Angle
Helix Angle
= =
Where p = pitch of the lead screw; D = pitch circle diameter; = Helix angle Driver teeth/Driven teeth = A/B X C/D (A and C are driving gears. B and D are driven gears)
1. 2.
3. 4.
5.
6.
Pitch diameter Addendum (large end) Dedendum (large end) Tooth depth (large end) Tooth thickness (large end) Circular pitch
Zm 1m
1.25 m 2.25 m
d ha
hd h
1.5708 m
s
p
Symbol b R
4.
5.
Dedendum angle
Pitch cone angle
a d
Special cutters
Gear Broaching
Gear Broaching
Template Method
Gear shaping
Gear shaping
Gear shaping
Gear shaping
Gear shaping
Gear Planing
Gear Hobbing
Hobbing is a process of generating a gear using a rotating tool called Hob. The hob has helical threads
The threads have grooves cut parallel to the axis to provide cutting edges.
The gear teeth are cut into the workpiece by a series of cuts made by the hob. It is the most widely used gear cutting process for creating spur and helical gears.
Gear Hobbing
Gear hobbing is a multipoint machining process in which gear teeth are progressively generated by a series of cuts with a helical cutting tool (hob). Both the hob and the workpiece revolve constantly as the hob is fed across the face width of the gear blank.
Hobs
Gear Hobbing
Gear Hobbing
Gear Hobbing
Gear Hobbing
Gear Hobbing
Gear Hobbing
Gear Hobbing
Gear Hobbing
Gear Hobbing
Gear Hobbing
Gear Shaving
Gear Grinding
Gear Grinding
Thank you!