3.

2 Gear Selection and Design

Referring to the Chapter 1 of the study, the proponents decided to manufacture spur gears

using our designed machine at certain diametral pitch, Pd , equal to 20 and different
teeth
number of teeth, N, of 120, 80, and 72. The selection of gear teeth is limited due to the
present physical dimensions of the lathe machine used in the USC machine shop. Further
increase in number of teeth will also increase the outside diameter of the gear which can be
explained in Eq.

On the other hand, the type of gear used is an involute full depth standard as used
according to the standard gear cutter available. For the calculation of the pitch diameter, Eq.
satisfies

N
Pd =
D

where both diametral pitch and the number of teeth is held constant since it is already been
decided as based in the limitations of the study. Also to determine the outside diameter, Do of
the gear, Eq. is used. Therefore,

N +2
D o=
Pd

The outside diameter of the gear is so important since not all available materials can be precisely
equivalent to it. Therefore it needs to be machined using a lathe equipment to acquire the
dimensions. For the calculation of root diameter of the gear, Eq. is used thus,

D r =D2 b

where b is the dedendum of the gear which can be determined using Eq. ,

1.200
b= +0.002(min .)
Pd

Also the tooth thickness of the gear can be found using the Eq.,

1.5708
t=
Pd
The entire calculation can be found in Appendix. For all the geometric data of the spur gear full
depth involute of a pressure angle, =14.5 , Table 3.1 shows the calculated value from the

teeth with tooth of 120, 80, and 72.

above equations using Pd =20

Table 3.1 Calculated Gear Geometries at given Pd and N.

This table will be further used during the design of the cutting tool profile using the Solidworks
software and for the tool bit guide.

Figure 3.1.Spur Gear design drawing using Solidworks at 80 teeth : (a) Front view; (b)
Detailed view
Figure 3.2.Spur Gear design drawing using Solidworks at 72teeth : (a) Front view; (b)
Detailed view.

Figure 3.3.Spur Gear design drawing using Solidworks at 120 teeth : (a) Front view; (b)
Detailed view.
 Figure 3.4. Three dimensional views of designed Spur gears: (1) N=120 teeth ; (2)
N=80 teeth ; (3) N=72 teeth .

Figure 3.4 shows the three dimensional views of the designed spur gears at various
number of teeth. Clearly the illustration also determines that at increasin number of teeth, the
spur gears have larger diameters or sizes. This can be explained when calculating the diameters
in Eq. where the number of teeth is directly proportional to the outside diameter of the gear. The
geometry of these gears are also shown in Figures 3.1, 3.2 and 3.3 given the calculated data from
Table 3.1. The following gears does not change its tooth thickness since Eq. is not dependent to
the any parameter except the diametral pitch. Also that the proponents of this study chooses a
diametral pitch of 20 to attain the proper size of the gear due to the limited geometries available
in the lathe machine during the manufacturing process.
3.3 Indexing Plate Design

Figure 3.2 shows the actual dimensions of the indexing plate to be attached in the lathe
machine at the back of the face plate near the chuck. Using the number of teeth of 120, 80 and
72, the indexing plate angle can be determined using the Eq.,

360
N

where N is the number of teeth of the gear. Also as seen in Figure 3.5, it primarily consists of
three offset wholes where the lower part is for spur gear teeth of 72, middle for 80, and upper for
120 number of spur gear teeth. Also the idea of the design uses a divisible factor possible for
360 angle to ease the division of angles during the fabrication process.

Figure 3.5. Indexing Plate Design: (a) Indexing plate; (b) Detailed view of the indexing whole.
3.4 Design of Cutting Tool (Tool bit)

3.4.1 Design of Cutting Tool Geometry

For the tool bit design, Solidworks software is used to develop the initial form of the
cutting tool for gear manufacturing. The design requires the geometric form of the gear as shown
in Chapter 2 Figure 2.6 where in between the profile of the tooth is cut the same way how the
milling machine manufactures a spur gear. The material of the tool bit used for this linear cutting
process of designed machine is HSS (High Speed Steel) type of steel. Figure 3.6 shows the actual
standard size of the HSS that can be bought in any distributing markets available.

Figure 3.7 shows the result of designing the cutting tool profile given the data above
using the Solidworks software. In tool bit designing, it uses a rake angle, , of 14 that
will be an effective angle used during the experimentation of power estimation with the tabulated
results to calculate the power consumption required to cut a single process of orthogonal cutting
[17]
. Also the Minor flank angle or the Working normal clearance, , has an angle equivalent
to 13.8 as a standard angle found in any market.

Figure 3.6. Standard Geometric Properties of HSS Cutting Tool with Minor Flank of 13.8
angle: (a.) Top View; (b.) Isometric View.
Figure 3.7. Design of Cutting tool using Solidworks Software: (a) Rake angle ( =14 ); (b)
Minor Flank angle or the Working normal clearance ( =13.8 ) ; (c) Rake face forming the
gear tooth profile.

3.4.2 Design of Cutting tool profile-guide plate

For the sharpening process of the tool bit to be used, a guide plate must be designed as a
reference to obtain the right geometric profile of the cutting tool as shown in Figure 3.4. Using
the tabulated data from Table 3.1, a spur gear is constructed with the Solidworks software
obtaining the tooth profile to be used in the plate. This plate will serve as the measuring gage
during the sharpening of the cutting tool.

Figure 3.9 also shows the actual positioning to follow the profile of the tool bit guide
plate into the tool bit. The tool bit must be properly postioned vertically to obtain the geometric
properties of the gear to be manufactured into the tool bit. Taking also into account the tolerance
possible when sharpening of toolbit is very important to obtain a high precision geometry during
the manufacturing process.
Figure 3.8. Tool bit Guide plate: (a) 2D view ; (b) Isometric view

Figure 3.9. Isometric view of the tool bit with the tool bit guide.