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GEARS MACHINING

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GEARS MACHINING GEAR TYPES Cylindrical gears: spur helical Bevel gears: straight curved (spiral) Worm wheels and worms * Gear lapping On finished, shaved and hardened ... – PowerPoint PPT presentation

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Title: GEARS MACHINING


1
GEARS MACHINING
  • GEAR TYPES
  • Cylindrical gears
  • spur
  • helical
  • Bevel gears
  • straight
  • curved (spiral)
  • Worm wheels and worms

2
Involute tooth profile
3
Spur and helical gears cutting
  • METHODS
  • form milling using a cutter (with the same edge
    profile as the shape of the tooth space) and a
    dividing device
  • hobbing using a hob and a generating process
    for creating a tooth profile
  • shaping using a shaper cutter and a generating
    process for creating a tooth profile
  • broaching

4
Gear machining form milling(single gear tooth
cutter)
5
Gear machining form milling
6
Gear milling tollerances and surface finish
Type of cut IT Ra
Form milling shape mill 9 11 3,2 - 6,3
End milling 8 - 9 3,2 - 6,3
7
Gear machining - hobbing
  • Hob a tool designed as a worm shaped cutter,
    which acts by the cutting as a worm cooperating
    with the machined gear wheel

8
Hobbing cutter
9
Gear hobbing
10
Gear hobbing
11
Gear hobbing machine tool
12
Gear hobbing machine tool
13
Gear hobbing kinematic schema
14
Gear machining - shaping
  • circular shaper cutter ?
  • rack shaper cutter
  • ?

15
Gear shaping a circular cutter
16
Gear shaping a circular cutter
17
Gear shaping the principle
18
Gear shaping a circular cutter
19
Gear shaping a rack cutter
20
Gear shaper with the rack cutter
21
Tollerances and surface finish
Type of cut IT Ra
Hobbing 5 - 7 0,8 3,2
Shaping circular cutter 5 6 0,8 1,6
Shaping rack cutter 4 - 5 0,8 1,6
22
Broaching
  • Very productive method
  • Broach has the shape of gear
  • Ideal for internal gears
  • Tooth gaps one after another
  • All gaps simultaneously

Desc. 1 elongated body, 2 teeth, 3
gullets, 4 teeth gaps, 5 axis, 6 follower
end, 7 pull end, 10 outside shape of broach
23
Broaching
  • From a premachined hole a final gear is made

24
Broaching
Type of cut IT Ra
Roughing 5 6 0,8 1,6
Finishing 4 - 5 0,8 1,6
25
Spur and helical gears finishing
  • METHODS
  • shaving for gears without heat treatment
  • grinding mostly for gears after heat treatment
  • - form grinding
  • - involute - generating grinding
  • lapping
  • teeth rounding creating a shape of tooth (in
    the direction parallely to the axis of rotation)
    to make changing gears easier

26
GEAR WHEELS SHAVING
  • A gear wheel being shaved is run in contact with
    a shaving cutter
  • Shaving cutter HSS tool teeth with serrations,
    which are acting in the shaving

27
GEAR WHEELS SHAVING
  • The gear and the cutter are run in mesh with
    their axes crossed at a small angle. During the
    rotation the gear is reciprocated longitudinally
    across the cutter.
  • This shaving process causes very fine chips are
    cut from the tooth surface (process requires less
    than 1 minute)

28
Form gear grinding
29
Form splining grinding
30
Involute-generating grinding
31
Involute-generating grinder
32
Involute-generating grinder
33
Gear finishing tollerances and surface finish
Type of cut IT Ra
Shaving 5 - 6 0,4 0,8
Form grinding 5 7 0,2 1,6
Involute-generating grinding with straight-sided grinding wheels 2 - 4 0,2 0,4
Involute-generating grinding with a worm grinding wheels 3 - 5 0,2 - 0,8
34
Gear lapping
  • On finished, shaved and hardened gears.
  • The gear runs in contact with one or more cast
    iron lapping gears
  • Flow of oil with abrasive is used
  • Improves surface quality at low costs then
    grinding
  • Ra 0,1 0,2

35
Teeth rounding
36
Teeth rounding
37
Straight bevel gears cutting
  • METHODS
  • form milling using a cutter (with the same form
    as the tooth face) and creating first one, than
    the opposite face flank of the tooth
  • involute-generating milling using two cutters
    representing one tooth of a rack and a generating
    process for creating a tooth profile
  • shaping using a shaping rack tool and a
    generating process for creating a tooth profile
  • broaching using rotational broach

38
Straight bevel gears involute-generating milling
39
Straight bevel gears - shaping
40
Straight bevel gears - broaching
41
Straight bevel gears - broaching
41
42
Curved bevel gears cutting
  • METHODS
  • Gleason teeth curved in the form of circle
  • Oerlikon teeth curved in the form of epicycloid
  • Klingelnberg teeth curved in the form of
    involute

43
Gleason method
  • Tool is a composition of a round body and cutting
    tools. The can be adjusted separatelly.

44
Curved bevel gears - Oerlikon
45
Curved bevel gears - Oerlikon
46
Worms and worm gears
  • Worms produced by turning or form milling

47
Worms and worm gears
  • Worm gears produced by hobbing
  • Worm hob has a small diameter
  • In feed machining

48
Odkazy youtube
  • Form milling
  • http//www.youtube.com/watch?vs4F8XzV8IrM
    5axis
  • http//www.youtube.com/watch?vRV8Dq6mslnEfeature
    fvw
  • Gear hobing
  • http//www.youtube.com/watch?vDwFssm9trScfeature
    related
  • http//www.youtube.com/watch?v2HfCxlSP0-gfeature
    related
  • http//www.youtube.com/watch?vj7dEtrN6TqMfeature
    related
  • Gear shaping
  • http//www.youtube.com/watch?vxF9CjluRFJ4feature
    fvw
  • http//www.youtube.com/watch?v_j6KQ96YZM0feature
    related
  • Bevel gear planing
  • http//www.youtube.com/watch?vAdi0GgUc2Z4NR1
  • Gleason bevel cutting
  • http//www.youtube.com/watch?vQq-0CePTt98feature
    related
  • http//www.youtube.com/watch?vjSYP1wTp4T4feature
    related
  • Worm turning
  • http//www.youtube.com/watch?vb81qJcZ9eTIfeature
    related

49
Odkazy youtube
  • Gear grinding
  • http//www.youtube.com/watch?vm6gRprNkTkY
  • Gear rounding
  • http//www.youtube.com/watch?v0xMYSXa7fsAfeature
    related
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