Gear manufacturing refers to the making of gears. Gears can be manufactured by a variety of processes, including casting, forging, extrusion, powder metallurgy, and blanking. As a general rule, however, machining is applied to achieve the final dimensions, shape and surface finish in the gear. The initial operations that produce a semifinishing part ready for gear machining as referred to as blanking operations; the starting product in gear machining is called a gear blank.[1]
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Selection of materials
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The gear material should have the following properties:[2]
Gear manufacturing processes
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There are multiple ways in which gear blanks can be shaped through the cutting and finishing processes.
Gear forming
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In gear form cutting, the cutting edge of the cutting tool has a shape identical with the shape of the space between the gear teeth. Two machining operations, milling and broaching can be employed to form cut gear teeth.[3]
Form milling
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In form milling, the cutter called a form cutter travels axially along the length of the gear tooth at the appropriate depth to produce the gear tooth. After each tooth is cut, the cutter is withdrawn, the gear blank is rotated, and the cutter proceeds to cut another tooth. The process continues until all teeth are cut
Broaching
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Broaching can also be used to produce gear teeth and is particularly applicable to internal teeth. The process is rapid and produces fine surface finish with high dimensional accuracy. However, because broaches are expensive and a separate broach is required for each size of gear, this method is suitable mainly for high-quality production.
Gear generation
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In gear generation, the tooth flanks are obtained as an outline of the subsequent positions of the cutter, which resembles in shape the mating gear in the gear pair. There are two machining processes employed shaping and milling. There are several modifications of these processes for different cutting tool used.[4]
Gear hobbing
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Gear hobbing is a machining process in which gear teeth are progressively generated by a series of cuts with a helical cutting tool. All motions in hobbing are rotary, and the hob and gear blank rotate continuously as in two gears meshing until all teeth are cut.
Finishing operations
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As produced by any of the process described, the surface finish and dimensional accuracy may not be accurate enough for certain applications. Several finishing operations are available, including the conventional process of shaving, and a number of abrasive operations, including grinding, honing, and lapping.[5]
See also
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References
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Valery Marinov, Manufacturing Technology, 2004, Gear manufacturing P123-P128
Machine Design II, Prof.K Gopibath& Prof.MM Mayuram, Lecture #5
Introduction to Gears, 2006, Kohara Gear Industry Co LTD
Step of Manufacturing Gear box
Gear Generation and Finishing Operations, Chap #6
My first lathe I rebuilt over 30 years ago, I had to make two pinion gears and a double bevel gear for the apron of that old lathe. The two pinion gears were a no brainer to make and did a nice job on them. I wish I had taken pictures of them. The double bevel gear was a little more difficult. Luckily, I got the factory cutters to make it. They had been resharpen so many times there wasn't much left to the cutter teeth. Slowly but surely, I was able to cut the bevel gears. How I go ahold of the factory bevel gear cutters, that's another story for later. Since that time I have replaced a couple of pinion gears with modified stock gears from Boston Gear. So far they are still holding up on my lathes today. Now if I can find a 127 tooth gear!
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