Gear Forming by Machining
Formation of gear through machining consists of following methods:
- Form Milling by Disc Cutter
- Form Milling by End Mill Cutter
- Shaper, Planner and Slotter
- Broaching
It is defined as, "Tooth is cut one by one by plunging the rotating cutter into the blank".
- Each gear needs a separate cutter.
- 8 - 10 standard cutters are available for producing 12 - 120 teeth gears.
- Used for big spur gears of large pitch.
It includes the cutting of tooth at a time and then indexed for the next tooth space for cutting.
- For a small volume production of low precision gears.
- Set of 10 cutters ↠ 12 - 120 teeth gears.
- Used for teeth of large gears/module.
- To reduce cost, same cutter is often used for multiple sized gears resulting in profile errors.
Characteristics:
- Use of Hardened stainless steels (HSS) form milling cutters.
- Use of Ordinary milling machines.
- Low production rate (need of indexing after machining, slow speed and feed).
- Gear having different modules and number of teeth need separate milling cutters.
- Low Accuracy and surface finish.
- Shaper ↠ Linear motion for cutting reciprocates parallel to the center axis of blank and cuts one tooth at a time. It is used for repair and maintenance purpose.
- Planning ↠ Machine for large gears.
- Slotting ↠ for internal gears.
Multi-toothed tool in which successive tooth takes a small cut but when all the teeth have passed over the gear blank to be machined.
- Internal, external spur gears, straight or single helical gears are produced in large quantity.
- External teeth are produced by broaching in one pass.
Note:
References:
- Material from Class Lectures + Book named Fundamentals of Modern Manufacturing Materials, Processes and Systems by Groover + My knowledge.
- Photoshoped pics are developed.
- Some pics and GIF from Google.
- Videos from YouTube (Engineering Sights).
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