GEAR HOBBING

SECTION 3
GROUP 6
ID No.

NAME

2013B4A4471P
2013B4A4607P
2013B3A4685P
2014A4PS012P
2014A4PS386P
2014A4PS417P
2014A4PS385P

SHUBHAM CHOUDHARY
SIDDHANT JAIN
SHUBHAM KHANDELWAL
SOURABH SINGH PANWAR
VISHWESH RAVI SHRIMALI
SUGUN TEJ INAMPUDI
VARUN KAUSHIK

ME F313
PRODUCTION TECHNIQUES II

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI, 333031

Experiment No: 02
GEAR MANUFACTURING USING HOBBING MACHINE
Objective:
Manufacturing a helical gear on a universal gear hobbing machine.

Equipment Used:
Universal gear hobbing machine, gray cast iron blank with outer diameter 101
mm, HSS hob cutter (RHS) with helix angle 2o15 and outer diameter 65mm.

Details of gear to be manufactured:

Required module = 2.5; helix angle = 18o

Theory:

Figure 1: Different terminologies associated with gears

A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which
mesh with another toothed part to transmit torque. Geared devices can change

the speed, torque, and direction of a power source. Gears almost always produce
a change in torque, creating a mechanical advantage, through their gear ratio,
and thus may be considered a simple machine. The teeth on the two meshing
gears all have the same shape. Two or more meshing gears, working in a
sequence, are called a gear train or a transmission. A gear can mesh with a linear
toothed part, called a rack, thereby producing translation instead of rotation.

There are a large number of types of gears available depending on the

application external and internal gears, spur gear, helical gear, double helical
gear, bevel gear, spiral gear, etc. Here we focus primarily on spur gears and
helical gears. Spur gears face high impact stress due to direct contact between
teeth and hence can transmit limited amount of power. Helical gears are of left
and right types. They operate much more silently as compared to spur gears and
since there is indirect compact between the left and right helical gears, they
have longer life and can transmit more power.
Pitch circle of a gear is the circle on which the point of contact between the two
gears lies. Pitch diameter is given by Dp.
D p=Douter 2 addendum=96 mm

Here, addendum has been taken as module (for full depth of cut).
The module of a gear is the ratio between the pitch circle diameter of the gear
to the number of teeth on the gear. This is a fundamental quantity for any gear.
It is given by m.
m=

Dp
cos ( )
T

Where T is the number of teeth and is the angle of helix.

m comes out to be around 36.
For a full depth of cut, dedendum, D = 1.25*m
Gears can be manufactured through casting, forging, extrusion, machining
through form cutting or through gear generation. The universal gear hobbing
machine has four different kinds of gear trains whose gear ratios we must
determine depending on the kind of gear we wish to manufacture. The different
gear trains are mainly for Speed, Indexing, Feed and a differential. For the given
specifications, we look up on the charts to find the gear ratios for all these gear
trains.

 Indexing gear train: 24*k/Z = (a*c)/(b*d) = 24/36 where k is the

number of starts (in case of a hob cutter its 1), Z is the number of teeth
required.
Feed gear train: This ratio is given by (3/10)*s where s is 2 for the given
conditions in mm/rev.
Differential gear train: The gear ratio is obtained by 3.97888*(sin
/m*k) = 53*45/54*47 approximately.
Speed gear train: The speed ratio depends on the material.

Remarks:
Advantages of Gear Hobbing over Milling:
Manual indexing in Milling
Involute profile will be damaged due to offset of cutter
Milling is slower
Mass production using hobbing due to no manual indexing
Difference between form cutting and generating gears:
Gear cutting uses a generalized milling machine or an all purpose
machine.
Gear generating requires specialized equipment like hobbing machine

Procedure:
Choose an available cast iron gear blank to cut helical teeth. Acc. to the
O.D of the blank available, the required normal module and helix angle
decide PCD, number of teeth, and the cutting speed.
Mount the desired hob cutter.
Calculate from the chart the speed gear ratio, index gear ratio and feed
gear ratio.
Set the above three ratios in the hobbing machine.
Provide the mill is with an angle and vertical displacement to initiate the
hob.

Conclusions:
The manufactured gear is precise.
The tooth dimensional accuracy is better than achieved using gear
generating milling cutter.

Faster process than gear generating