PRESENTANTION PROCESSES AND PRACTICE II

GEAR MILLING BY GROUP E {H.N.D} MECH ONE

GROUP MEMBERS
NAMES
ISREAL .L.K. SAM GERALD .A. LARBI RICHARD .K. LAING KINGSFORD.A. BAIDEN FRANK .O. ANOKYE DODWINE .E. APPIAH HANNAH GHANSAH RICHARD QUAICOE KWEKU.B. NTARMAH EMMAUEL DOKOR ANTHONY .A. AMERIGA

INDEX NUMBERS
07098303 07098314 07098322 07098334 07098545 07098349 07098350 07098387 07098390 07098391 07098359

OBJECTIVES
At the end of the lecture, students should: Know what a gear is Identify various types and uses of gears Know types of gear cutting methods Identify cutters used for cutting gears understand the principles of indexing Understand the principles of cutting gears on a milling machine.

INTRODUCTION
Gears are mechanical devices used to transmit power positively from one shaft to another by means of successively engaging their teeth. They are used in place of belt drives and other forms of friction drives when exact speed ratios and power transmissions must be maintained. Some gear cutting machines include, the gear shaping machine and the gear hobbing machine. However, this topic will discuss on cutting gears on the milling machine. Most gears cut on the milling are generally used to repair or replace a gear which has been broken, lost or no longer carried in inventory.

GEARS

Gears are mechanical toothed wheels devices or cylinder used to transmit power positively from one shaft to another by means of successively engaging the teeth. They are used in places of belt drive and other forms of friction drivers when exact speed ratios and power transmission must be maintained. They may also be used to increase or decrease the speed of the driven shaft.

Fig .[a] shows a gear

TYPES OF GEARS
Spur gear Bevel gear Internal gear Helical gear TYPES OF GEAR ARRANGMENT
Worm gear Rack and pinion gear

SPUR GEAR : This type of gears are generally used to transmit power between two parallel shafts, the tooth on the gear are straight and parallel to the shaft to which they are attached.

USE Spur gears are used where moderate speed drivers are required. They are used to transmit power between two parallel lines.

Fig.1 a. A spur gear

BEVEL GEARS : Are used to transmit power when two shaft are located at an angle with their axial lines intersecting at 90 degrees. When the shaft are at right angles and the gears are the same size, they are called mitter gears. If the axes of the shaft intersect at any angle other than 90 degrees they are known as angular bevel gears.

Fig. (c)Bevel gear

USES They are used for automatic drives.

WORM AND WORM GEAR : These are used when the shafts are at right angles and considerable reduction in speed is required.

Fig. 6 worm and worm gear

USES The worm and worm gear is use to reduces end thrust.

RACK AND PINION : Are used when it is to convert rotary motion to linear motion. The rack which is actually a straight or flat gear may have straight teeth to mesh with a spur gear or angular teeth to mesh with a helical gear.

Fig. 7 rack and pinion gear

Rack and pinions are commonly used in the steering system of cars to convert the rotary motion of the steering wheel to the side to side motion in the wheels. Rack and Pinions are also used in adjustable spanners

HELICAL GEARS: Are used to connect parallel shafts or shafts which are at angles. Since there is more than one tooth in engagement at one time, helical gears are stronger than spur gears. Helical gears run more smoothly and quietly than spur gears.

Fig 8. helical gear

Helical gears are designed to eliminate the end thrust and provide long life under heavy loads.

GEAR TERMINOLOGY
ADDENDUM: Is the radial distance between the pitch circle and the outside diameter or the height of the tooth above the pitch circle. CENTER DISTANCE: Is the shortest distance between the equal to one-half the sum of the pitch diameters. CHORDAL ADDENDUM: Is the radial distance measured from the top of the tooth to a point where the chordal thickness and the pitch circles intersect the edge of the tooth. CHORDAL THICKNESS: Is the thickness of the tooth measured at the pitch circles or the length of the chord which subtends the arc of the pitch circle. CIRCULAR PITCH: Is the distance from a point on one tooth to a corresponding point on the next tooth measured on the pitch circle.

CLEARANCE: Is the radial distance between the top of one tooth and the bottom of the mating tooth space. DEDENDUM: Is the radial distance from the pitch circle to the bottom of the tooth space . The dedendum is equal to the addendum plus the clearance. DIAMETRAL PITCH: (Inch gears) is the ratio of the number of teeth for each inch of pitch diameter of the gear. INVOLUTE : Is the curved line produced by point of a stretched string when it is unwrapped from a given cylinder. LINEAR PITCH: Is the distance from a point on one tooth to the corresponding points on the next tooth of a gear rack. MODULE (Metric gears): Is the pitch diameter of a gear divided by the number of teeth.

OUTSIDE DIAMETER: Is the overall diameter of the gear, which is the pitch circle plus two addendums. PITCH CIRCLE: Is a circle which has the radius of half pitch diameter with its center at the axis of the gear. PITCH CIRCUMFERENCE: Is the circumference of the pitch circle. PITCH DIAMETER: Is the diameter of the pitch circle which is equal to the outside diameter minus two addendums. PRESSURE ANGLE: Is the angle formed by a line through the point of contact of two mating teeth and tangent to the two base circles and a line at right angles to the centre line of the gears. ROOT CIRCLE : Is the circle formed by the bottoms of the tooth space. ROOT DIAMETER : Is the diameter of the root circle.

WHOLE DEPTH: Is the full depth of the tooth or the distance equal to the addendum plus dedendum. WORKING DEPTH: Is the distance that a gear tooth extends into the tooth space of a making gear which is equal to two addendums.

RULES AND FORMULAE FOR SPUR GEAR

TO OBTAIN
Addendum[A] Center distance [CD]

KNOWING
Circular pitch Diametral pitch Center pitch

RULE
Multiple the circular pitch by 0.3183 Divide 1 by the diametral pitch Multiple the number teeth in both gears by the circular pitch, and divide the the product by 6.2832 Divide the total number of teeth in both gears by twice the diametral pitch Subtract from 1 the cosine of the result of 90 divided by the number of teeth. Multiply this result by half the pitch diameter. To this product add the addendum. Divide 90 by the number of teeth, find the sine of this result and multiply by the pitch diameters.

FORMULAR
A= CP0.3183 A= 1 / DP CD=[N+n]CP/6.2832

Diametral pitch Chordal [corrected] addendum [CD] Chordal thickness[CT] Pitch diameter addendum and number of teeth Pitch diameter and number of teeth

[N+n]/ [2DP] CA=[1- cos90/N] PD/2 ]+A

CT= sin[90/N]PD

Circular Pitch

Center to center distance

Multiply center to center distance by 6.2832, and divide the product by the total number of teeth in both gears.

CP=[CD6.2832]/ N+n

TO OBTAIN CIRCULAR PITCH (CP)

KNOWING Diametral pitch

RULE Divide 3.1416 by the diametral pitch

FORMULAR CP=3.1416 DP CP + PD x 3.1416 N CL= CP 20

Pitch diameter and number of teeth CLEARANCE (CL) Circular pitch

Multiply pitch diameter by 3.1416 and divide by the number of teeth. Divide circular pitch by 20.

Diametral pitch

Divide 0.157 by the diametral pitch.

CL = 0.157 DP D= CP x 0.3683 D= 1.157 DP DP = 3.1416 CP DP = N + 2 OD DP= N PD

DEDENDUM (D)

Circular pitch Diametral pitch

Multiply the circular pitch by 0.3683 Divide 1.157 by the diametral pitch

DIAMETRAL PITCH (DP)

Circular pitch

Divide 3.1416 by the circular pitch.

Number of teeth and outside diameter Number of teeth and pitch diameter

Add 2 to the number of teeth and divide the sum by the outside diameter. Divide the number of teeth by the pitch diameter.

Example Calculate the pitch diameter, outside diameter and whole depth of teeth for the following gears. [a] 8 DP with 36 teeth. [b] 12 DP with 81 teeth. [c] 16 DP with 100 teeth. Solutions [a] Pitch Diameter DP= N/DP= 36/8 DP= 4.5 mm Outside Diameter OD= N+2/DP =[ 36+2]/8 OD = 4.75 mm Whole Depth WD = 2.157/DP = 2.157/8 WD = 0.26962 mm

INVOLUTE GEAR CUTTERS This type of gear cutter is shaped on the face and ensures exact duplication of the shape of the teeth, regardless of how far back the face of the tooth has been ground. Gear cutters are available in many sizes, ranging from 1 to 48 diameter pitch (DP). When gear teeth are cut on any gear, a cutter must be chosen to suit both the DP and the number of teeth (N). The teeth on smaller gear must be more curved to prevent binding of meshing gear teeth. Therefore sets of gear cutters are made in series of slightly different shapes to permit the cutting of any desired number of teeth in a gear, with the assurance that this those of another gear of the same DP.

 The cutters are generally made in sets of eight and are numbered from 1 to 8. There is gradual change in shape from the number 1 cutter, which has almost straight sides to the much more curved sides of the number 8 cutter.

It should be noted that in order for gears to mesh, they must be of the same DP. Same gear cutter manufacturers have augmented the set of eight cutters with seven additional cutters in half sizes making a total of 15 cutters in the set, numbered 1, 1.5, 2,pe2.5 etc. Example : A 10-DP gear and pinion in mesh have 100 teeth and 24 teeth respectively. What cutters should be use to cut these gears? solution Since the gears are in mesh both be cut with a 10-DP cutter. a. A number 2 cutter should be used to cut the 100 teeth gear, since it will cut from 55 to 134 teeth. b. A number 5 cutter should be used to cut the pinion (24 teeth), since it will cut from 21 to 25 teeth

Fig. 9 involute gear cutter

METRIC MODULE GEAR CUTTERS

The most common metric gear cutters are available in modules ranging from 0.5 to 10mm. However, metric modules gear cutters are available in sizes up to 75mm. Any metric module size is available in a set of eight cutters, numbered from number 1 to 8. The range of each cutter is the reverse of that of a DP cutter. For instance, a number 1 metric module cutter will cut from 12 to 13 teeth; a number 8 cutter will cut from 135 to a rack.

INVOLUTE GEAR CUTTERS

Cutter Number Range

1 1
2 2 3

135 teeth to rack 80 to 134 teeth 55 to 134 teeth 42 to 54 teeth 35 to 54 teeth

3
4 4 5 5 6 6

30 to 34 teeth
26 to 34 teeth 23 to 25 teeth 21 to 25 teeth 19 to 20 teeth 17 to20 teeth 15 to 16 teeth

7
7 8

14 to 16 teeth
13 teeth 12 to 13 teeth

INDEXING
Milling Machine Indexing. Positioning a workpiece at a precise angle or interval of rotation for a machining operation is called indexing.

DIRECT INDEXING It is the simplest form of indexing, but its use is limited. Each dividing head has a direct index plate attached to its spindle so that the ratio of its movement is 1:1 with the spindle. Direct index plates have 24 equally spaced holes. The 24 hole direct indexing plate can be used for dividing a circle into 24, 12, 8, 6, 4, 3 or 2 equal divisions. Dividing the number of holes that must be indexed. For example, to cut a square on the end of a shaft: 24 4 = 6. Indexing 6 holes for each cut will produce the desired square. Angles in multiples of 150 can also be indexed. Dividing 150 into the angle desired gives the number of holes to be indexed for moving the number of degrees desired. Example 1200 15 = 8 holes.

 For direct indexing, first retract the index plunger pin from the index plate. Rotate the index plate through the number of spaces desired by turning the index crank. Then, reinsert the plunger pin in the hole in the index place. On some dividing heads, it is possible to disengage the worm gear attached to the index crank. When the quick index plunger pin is withdrawn, the direct index plate can be moved by hand without turning the index crank which provides faster indexing. After each desired turn of the direct index plate, the quick index plunger pin must be engaged to hold the plate in position.

PLAIN INDEXING
This is also called simple indexing and it makes it possible to index many divisions not possible by the direct indexing method. Divisions of 5, 7, 9, 11, 13 and many other numbers of equally spaced divisions can be indexed by the plain indexing method. The worm shaft must be engaged with the work spindle for plain indexing. The work spindle is turned by withdrawing the index plunger pin and turning the index crank. The plunger pin is then set again while the work piece is milled. The index plate has several circles of holes. A different number of holes is equally spaced on each hole circle. Some dividing heads have holes on each side of the index plate. The plate may be reversed for the desired hole circle.

 The following formula can be used to determine the number of revolutions of the index crank for a desired number of equally spaced divisions. T = 40 N where T number of turns, or fractional part of turns of the index crank. 40 number of teeth on the worm wheel N number of divisions desired.

 Sample calculation Determine the number of revolutions of the index crank for indexing each tooth space for an 20 tooth spur gear. Solution

T = 40 N T = 2 turns

40 20

TAIL STOCK
This is bolted to the table and is used with the dividing head for holding a work piece between centres. Both the tailstock and the dividing head are equipped with 600 centers, the same as lathe centres. The tailstock center can be raised above the center point of the dividing head. This operation is done when tapered grooves or tapered surfaces are to be machined on a workpiece. In a typical dividing head operation, a workpiece such as the gear blank is pressed on a lathe mandrel. The mandrel is mounted between the centers of the dividing head and the tailstock.

fig.

Indexing head and tailstock set up on a milling machine's table.

DIVIDING HEADS Dividing heads, or index heads are employed in operation onknee-type milling machines for setting the work piece at the required angle to the table of the machine, turning the work piece through a predetermine angle, dividing a circle into the required number of parts (indexing) and also for continuous rotation of the work piece in milling helical grooves with a large lead.

TYPES OF DIVIDING HEADS DIRECT INDEXING DIVIDING HEAD This is also called plain dividing head; it is used for direct indexing into a small number of parts. It has a housing in which a spindle is rotatably mounted. The spindle carries an index plate, by means of which the counting of divisions is done during the indexing.

Direct Indexing Plate

UNIVERSAL DIVIDING HEAD

This is classified as head with and without an index plate. Index plate dividing head is widely or more used. Universal dividing head can be employed for simple and differential indexing.

Fig 11 universal dividing head

GEAR CUTTING Most gears cut on a milling machine are generally used to repair or replace a gear which has been broken or lost or is no longer carried in inventory. Industry generally mass produces gears on special machines which have been designed for this purpose. The most common types of gear generating machines are the gear shaping machines and the gear hobbing machines. It is generally more economical to buy gears from a firm which specializes in gear manufacture. Fasten the indexing fixture to the milling machine table. Use a mandrel to mount the gear between the index head and footstock centers.

 Adjust the indexing fixture on the milling machine table or adjust the position of the cutter to make the gear axis perpendicular to the milling machine spindle axis. Fasten the cutter bit that has been ground to the shape of the gear tooth spaces in the fly cutter arbor. Adjust the cutter centrally with the axis of the gear. Rotate the milling machine spindle to position the cutter bit in the fly cutter so that its cutting edge is downward. Align the tooth space to be cut with the fly cutter arbor and cutter bit by turning the index crank on the index head. Proceed to mill the tooth in the same manner as milling a keyway.

SETTING THE TOOL OVER THE BLANK

W
cutter

blank

WHERE W- cutter diameter D- blank diameter X- distance between the center of the cutter and the blank

X= W+D 2

Holding work between centres

PRECAUTIONS TO BE TAKEN WHEN CUTTING A GEAR Check that the blank and its mandrel run true so that the teeth are concentric with the axis of the gear Make sure that the cutter is sunk into the blank to the correct depth. This is usually marked on the side of the cutter, but it can be calculated by multiplying the module pitch by 2.25. For example the depth of cut for an 8mm cutter is 8 x 2.25 = 18mm

 One method of centering the cutter is raising the knee so that cutter can be brought into contact with the side of the wheel blank as shown by the full circle, and actual contact is obtained by feeding the saddle across until the rotating cutter just touches the blank. The readings of the cross traverse and knee-elevating dials are noted. The knee is lowered and the table is traversed across for a distance slightly greater than x. The knee is raised to its original height and the table is traversed across until contact is again made with the blank. The difference between the first and second readings of the cross traverse dial is the distance x.

CUTTING A SPUR GEAR The procedure for machining a spur gear is outlined in the following example above. Example A 52 tooth gear with an 8 DP is required. Procedure Calculate all the necessary gear data. Outside diameter = Number of teeth (N) + 2 =52 + 2 DP = 6.750

 b.

Whole depth of tooth = 2.157 DP

= =

2.157 8 0.2697

Cutter number = 3 (35 to 54 teeth) d. Indexing (using standard plate)=

40 N 52 = 10 3 = 30 holes 13 3 = 39 - holes Turn the gear blank to the proper outside diameter (6.750in). Press the gear blank firmly onto the mandrel. Note. If the blank was turned on a mandrel, make sure it is tight because the heat caused by turning might have expanded the blank slightly.

40 =

 Mount the index head and footstock and check the alignment of the index centers. Set the dividing head so that the index pin fits into the hole on the 39 hole circle and the sector arms are set for 30 holes. Note. Do not count the hole in which the pin is engaged. Mount the mandrel (and workpiece) with the large end toward the indexing head between the index centers. Move the work clear of the cutter by means of the longitudinal feed handle and raise the table to about two thirds the depth of the tooth (0.180in) then lock the knee clamp. Note. A special stocking cutter is sometimes used to rough out the teeth.

 Slightly notch all gear teeth on the end of the work to check for correct indexing. Rough out the first tooth and set the automatic feed trip dog after the cutter is clear of the work. Return the table to the starting position. Note. Clear the end of the work with a cutter. Cut the remaining teeth and return the table to the starting position. Loosen the knee clamp, raise the table to the full depth of 0.270in and lock the knee clamp. Note. It is advisable to remove the crank from the knee elevating shaft so that it will not be moved accidentally and change the setting. Finish cut all teeth. Note. After each tooth has been cut, the cutter should be stopped before the table is returned to prevent marrying the finish on the gear teeth.

KEYS AND KEYWAYS. A key is a component inserted between a shaft and a hub of a pulley, wheel etc. to prevent relative rotation by allowing sliding movement along the shaft if required. Keys are made of steel in order to withstand the considerable shear and compressive stresses caused by the torque they transmit. Keyways are recess machined in a shaft or hub to accommodate a key. Keyways can be milled horizontally or vertically. TYPES OF KEYS. There are two basic types of keys. Namely: 1. Sunk keys. 2. Saddle keys.

SUNK KEYS. Sunk keys are made to sunk into the shaft for half its thickness. These keys are suitable for heavy duty, since they rely on positive drive. TYPES OF SUNK KEYS. Various types of sunk keys include: 1.Feather key. 2.Woodruff key. 3.Rectangular and square key. 4.Splinded shaft.

SADDLE KEYS.

Saddle keys are sunk into the hub only. These keys are suitable only for light duty, since they rely on friction drive alone. TYPES OF SADDLE KEYS The types of saddle keys include: 1. Hollow saddle keys. 2.Flat saddle keys. 3.Round keys. HOLLOW SADDLE KEYS: They are used for very light duty.

Fig.12

Fig 12

FLAT SADDLE KEYS: They are used for light duty. Fig. 13

Fig. 13

ROUND KEYS: They are used for medium duty. Fig. 14

Fig.14

RECTANGULAR AND SQUARE KEY: They are used for heavy duty applications. Gib heads are provided on these keys to facilitate its removal. Fig. 15

SPLINED SHAFT: It is used when the hub is required to slide along the shaft. They are used mostly for sliding gear applications. Fig. 16

METHODS OF MOUNTING A GEAR ON A SHAFT To mount a gear on a shaft, the following must be taken into consideration: 1. Check the depth of cut. 2. Check for tolerance(slide fit or push fit). 3. Clear any foreign material using file. 4. There should be no bent on the shaft. 5. Apply grease in between the shaft and the gear. 6. The size of the gear teeth must be equal to enhance equal depth of cut

REFERENCE
W.A.J Chapman, Workshop Technology, Part 3, 1984. Steve .S. Krar, Technology of machine tools, fourth edition, 1990. Internet, jpegk moddi. library. Cornell. edu.

TO GOD BE THE GLORY