A free powerpoint ppt presentation displayed as a flash slide show on id. The surface of gear teeth produced through forming or generation process is not very accurate and properly finished. Gear burnishing has become a valuable method of gear tooth surface improvement. Hello everyone welcome to engineers academy topics covered.
Tooth space is produced in single stroke more blanks can be mounted at a time. Gear generation and unit 6 gear generation and finishing finishing operations operations structure 6. Explanation of gear finishing processes including honing, lapping, shaving, burnishing, sand blasting, grinding, shot blasting, shot peening. Advanced gear manufacturing and finishing sciencedirect. The work is pressed hard against the wheel or vice versa. The most common gearcutting processes include hobbing, broaching, milling, and. Unit 6 gear generation and finishing gear generation and.
In this process, a pinion shaped cutter is used, which is mounted with its axis vertical and is reciprocate up and down. Gear honing is a finishing method for hardened gears the grain size of the abrasive with which it is charged is selected to suit the honing allowance 01025 to 0. Manufacturing of gears is a very interesting area involving various methodologies and varies with the type of gears to be produced. Bevel gear precision forging production line according to user requirements for the bevel gear accuracy, the forging process is also very different.
Gears are critical parts to complex systems and machinery, and they require surfacefinish standards that make them fit and work with interrelated components. Drawing, texturing, intermingling and heat setting process drawingstretching. Specifically, hobbing, milling, and shaping are defined, as well as the four primary types. Drawing is a process in which a group of slivers or filaments is elongated by passing them through a semiseries pair of rollers godet pairs, each pair of roller moving faster than the previous one. A gear shaving tool is of a type of rack or pinion having hardened teeth provided with serrations. Scribd is the worlds largest social reading and publishing site. 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. Chapter 1, basic understanding of gears, discusses the various types of gears used, important gear nomenclature, and applied stresses and strength requirements associated with gears. This shaving processcauses very fine chips are cut from the tooth surface process requires less than 1 minute.
Gear wheels shaving the gear and the cutter are run in mesh with their axes crossed at a small angle. Gear icons can be quite handy for making diagrams that can enable presenters to point out how a specific process works or to show synergy and teamwork. Broaching tool is used in vertical broaching machine. The isf treatment is an industryleading process that uses mass finishing equipment with nonhazardous chemical accelerants to surface treat ring and pinion sets. During the rotation the gear is reciprocated longitudinally across the cutter. Also, the cutter and the gear blank both are rotated slowly about their own axis. Create powerpoint gears in 1 minute presentation process. Gears are widely used in various mechanisms and devices to. Broaching is a machining process that uses a toothed tool, called a broach, to remove material. Gear cutting gear cutting is any machining process for creating a gear.
Ppt gear powerpoint presentation free to download id. Gear lapping is the process of imparting a very fine finish and high degree of accuracy to gear teeth, by using a lapping tool and applying a finegrained abrasive between a work material and a closely fitting surface, called a lapping plate. In this video we have done with the practical manufacturing of the gear hobbing, please check how the gear hobbing is. Advanced gear manufacturing and finishing offers detailed coverage of advanced manufacturing technologies used in the production of gears, including new methods such as spark erosion machining. In this tutorial we will be learn surface finishing process part2. However, because broaches are expensive and a separate broach is required for each size of gear,this method is suitable mainly for highquality production. Originally titled nextgeneration gear finishing vibratory finishing, centrifugal barrel finishing and turboabrasive machining are the three top techniques for finishing gears, improving performance and extending service life. In cold roll forming, higher pressures are needed as compared to not rolling many of the gears produced by this process need no further finishing. The isf process can accommodate extremely small precision gears gear module 0. The cutter has outline same as that of the shape of the profile. Metal finishing objectives list key chemicals associated with metal finishing. Advanced gear manufacturing and finishing offers detailed coverage of advanced manufacturing technologies used in the production of gears, including new methods such as spark erosion machining, abrasive water jet machining, additive layer manufacturing, laser shaping, and sustainable manufacturing of.
It is designed to remove or reduce gear tooth nicks and burrs, along with improving the smoothness of. Burnishing is a polishing and work hardening of a metallic surface. This article describes the various methods of manufacturing methodologies followed for each type of gear. Gears play a prominent role in the mechanical power transmission.
Ppt gears machining powerpoint presentation free to. Drawing, texturing, intermingling and heat setting process. Disadvantage after shaving, the gear should be finished by gear grinding to get high quality surface finish on the tooth profile it is time consuming process. Generally, passenger car transmissions are provided with 45 forward speeds and one reverse speed. Lecture 5 gear manufacturing contents of the lecture gear manufacture can be divided into two categories, forming and machining. The modern flat gears powerpoint template is a presentation template which provides editable gear illustrations. This is achieved by removing just the thin amorphous surface layer left by the last process with an abrasive stone or tape.
The use of computer numerical controlled cnc equipment ensures a high precision synchronous relationship between the tool spindle and the work spindle as well as other motions, thereby eliminating the need for gear trains. Process progressively cuts the teeths in the gear by using a cutting tool known as hob. Features of surface texture surface roughness it refers to small, finely spaced deviations from nominal surface that are determined by the material characteristics and the process used. Make any gear you want by following three simple steps. Gear blanks and even gears along with teeth requiring substantial to little machining or finishing are produced by various casting processes.
This is a desirable characteristic in clockmaking and. Used on hard materials such as ceramics, cemented carbides and glass. Also, the cutter and the gear blank both are rotated. According to steve fussell, manufacturing manager, the primary benefit of grinding for gear production has historically been the improved gear quality after heat treating to produce nearperfect symmetry and micro finish, which results in very quiet gears.
What are all the types of gear finishing processes. Machining involves roughing and finishing operations. This process will smooth and harden the surface, creating a finish which will last longer than one that hasnt been burnished. S of gear shaving the rotary gear shaving process uses a gashed rotary cutter, fig. Various gear finishing methods gear grinding abrasive. Different gear combinations are used to give the smooth running, the lower fuel consumption, and the optimum driving comfort.
This video tutorial will be very helpful to our engineering students. Gear tooth honing is a gear finishing process that improves the surface finish of the tooth profile and reduces the noise of spur and helical gears after heat treatment. Superfinishing, also known as micromachining, microfinishing, and shortstroke honing, is a metalworking process that improves surface finish and workpiece geometry. These serrations serve as cutting edges which do a scrapping operation on the mating faces of gear to be finished. A gear may be finished in several different ways, such as lapping or grinding. Gear finishing by shaving, rolling and honing, part i. Various gear shaping processes are listed and then described below. Ppt grinding powerpoint presentation free to view id. Gear tooth honing is a gear finishing process that. The process also improvesmoth surface finish and eliminates, by crowned tooth forms, the danger. After grinding, whats left for gear hobbing, shaping and. Know the differences between gear finishing processes american. The rotary gear sbaving process gear shaving is a freecutting gear finishing operation that removes small amounts of metal from the working surfaces of gear teeth it purpose is to correct errors inindex, helix angle, tooth profile, and eccentricity fig.
A gear box transmits the engine power to the driving wheels with the help of different gearing systems. We will create this shape using shape union and shape subtract functions in powerpoint 2010 or higher versions of powerpoint. It is also necessary as a finishing process after many roughing operations. Metal finishing process barrel method electroplating. Forming consists of direct casting, molding, drawing, or extrusion of tooth forms in molten, powdered, or heat softened materials. Honing is an abrasive machining process that produces a precision surface on a metal workpiece by scrubbing an abrasive stone against it along a controlled path. It is true shape generation process in that the gear shaped tool cuts itself into mesh with the gear blank.
Function and quality with the bore in a control wheel, i. Hard gear finishing hgf, a relatively new technology, represents an advance in gear process engineering. It is a gear finishing process in which the gear are run together in. The high centrifugal forces and speed of this process achieve high. Discover a super easy way to draw gears using powerpoint 2010. Gear honing gear tooth honing is a gear finishing process that improves the surface finish of the tooth profile and reduces the noise of spur and helical gears after heat treatment. This process is the most versatile of all gear cutting processes. In not roll forming, the not rolled gear is usually cold rolled which compiles the gear with a smooth mirror finish. In linear broaching, which is the more common process, the broach is run linearly against a surface of the workpiece to effect the cut. For the love of physics walter lewin may 16, 2011 duration.
Gear shaving process of finishing of gear tooth by running it at very high rpm in mesh with a gear shaving tool. As a result of the constantly arising quality requirements on the final machining quality and the running behavior of hardened gears, the former totally dominating part of softshaving with geometrically welldefined cutting edges as final manufacturing step is steadily decreasing for the benefit of hard finishing by abrasive processes. The process of gear shaving back to basics from janfeb. Roll finishing coldforming process for helical gears. Chapter 42 43 gear manufacturing chapter 42 44 gears transmit power and motion mechanically. Gear honing is a finishing method for hardened gears the grain size of the abrasive with which it is charged is selected to suit the honing allowance 0025 to 0. The process is rapid and produces fine surface finish with high dimensional accuracy. Broaching can also be used to produce gear teeth and is particularly applicable to internal teeth. Gear finishing by abrasive processes sciencedirect. There are multiple ways in which gear blanks can be shaped through the cutting and finishing processes.