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gear milling

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by

Bruce Wayne

on 18 June 2014

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Transcript of gear milling

Structure
Manufacturing operations
gear milling
Gear Shapes
Spur
Form Milling
cutter travels axially along the length of the gear tooth
each gear tooth is cut one by one
process continues until all teeth are cut
Hobbing
teeth are progressively generated by a series of cuts
hob and gear blank rotate continuously until all teeth are cut
all motions are rotary
used for external gears
relatively inexpensive and most used gear cutting process
it is used for a broad range of parts and quantities


Skiving
Heavy duty cutting technique
Combination of hobbing and pushing
Continuous gearing technique
External and internal toothing
Used for Spur and bevel toothing
Toothing diameter up to 700 mm and module up to 8 mm
Capable for small series and mass production

Outlook
Gear Types, Spur, Helical, Bevel, Rack and Pinion, Worm. Online verfügbar unter http://www.engineersedge.com/gears/gear_types.htm, zuletzt aktualisiert am 17.06.2014, zuletzt geprüft am 17.06.2014.
Weck, M./Brecher. C. (2005): Werkzeugmaschinen Maschinenarten und Anwendungsbereiche. 6th Edition, Springer 2005
SCUDDING® von Innenverzahnungen. Online verfügbar unter http://www.profilator.de/profilator/technologien/scudding-innenverzahnung.html, zuletzt aktualisiert am 17.06.2014, zuletzt geprüft am 17.06.2014.

Pictures
http://backgroundimages.eu/albums/render-background/sprocket-gray-.jpg
http://image.made-in-china.com/2f0j00CSzEjVUsLqkw/Industrial-Spur-Gear-M1-M2-M3-M4.jpg
http://image.made-in-china.com/4f0j00FeYQmtfKYVbE/Printing-Machine-Helical-Gear.jpg
http://somitabg.com/images/Products/2.jpg
http://en.wikipedia.org/wiki/Spiral_bevel_gear#mediaviewer/File:Gear-kegelzahnrad.svg
http://images.vogel.de/vogelonline/bdb/402700/402745/4.jpg
http://shop.mikado-heli.de/k_mikado_e/prodpic/Pinion-for-herringbone-gear-11teeth-M1-dia-6mm-14mm-04635_b_0.JPG
https://www.thedailybrick.co.uk/media/catalog/product/cache/1/image/700x700/9df78eab33525d08d6e5fb8d27136e95/l/e/lego_gear_rack_4__3743__lego-black-gear-rack-4-3743-30-60882-38.png
http://www.maedler.nl/Image/250-250/Bilder_Ecomm/Productpics/Hohlschnecken.jpg.ashx
http://www.chibadies.co.jp/en/products/img/contents03_photo03_b.jpg
http://www.otto-junker.de/data/2/media/images/Edelstahlgiesserei_97b.jpg
http://www.mz-web.de/image/view/2012/9/15/21234582,17162328,dmData,Sintern+%25281349164437029%2529.jpg
http://www.ilsam.it/images/stampaggio/stampaggio_ilsam_10.jpg
http://forgingmagazine.com/site-files/forgingmagazine.com/files/imagecache/large_img/uploads/2013/03/bevelgearforgingshateburhotmatic35.jpg
http://www.doitpoms.ac.uk/tlplib/metal-forming-2/figures/extrusion_sml.jpg
http://custom-metal-products.deecometals.com/ImgMedium/gear-shape-extrusion.jpg
http://www.ukgeartec.de/mediac/400_0/media/DIR_3696/DSC00009.JPG
http://www.czf-getriebe.de/typo3temp/pics/9b9a96c34d.jpg
http://img.directindustry.com/images_di/photo-g/gear-hobbing-machines-53255-4896587.jpg
http://www.ibms-web.de/_pics/283/originalWaelzschaelen_2.jpg
http://www.rollstar.com/images/raeumen_von_innenverzahnungen.jpg
http://www.ctemag.com/aa_pages/2013/1302-Milling-web-resources/image/120294_opt.jpeg
http://www.iwasa-tech.com/product/img/DSC_0449.jpg
http://www.samputensili.de/media/SU/Machines/S150-400/S150-S400_010_web.jpg
http://www.kapp-coburg.de/__we_thumbs__/1951_6_wz_bearb.verf._waelz_bild.leiste2.jpg
http://www.bmpcoe.org/bestpractices/internal/fores/images/fores_01.jpg
http://www.star-su.com/media//SU/images/GRONO_250_detail_web1.jpg
http://img.directindustry.com/images_di/photo-g/lapping-machines-9207-6050461.jpg
http://img.directindustry.de/images_di/photo-g/schrupp-fraser-zahnrad-14460-2753251.jpg
http://www.industrieanzeiger.de/image/image_gallery?img_id=38591011
http://www.mav-online.de/image/image_gallery?img_id=33106158
http://www.ibms-web.de/_pics/288/originalWaelzschaelen.jpg
Sources
Crown
Gear Materials and Tasks
Gear Shapes
Manufacturing Operations
Form Milling
Hobbing
Skiving
Outlook
Sources
Helical
Spiral Bevel
Herringbone
Bevel
Rack
Non-circular
Worm
Non-machining
Casting
Sintering
Forging
Blanking
Rolling
Extrusion
Machining
Hobbing
Skiving
Broaching
Form Milling
Pushing
Plane by the Generating Method

Finishing
Scalp Hobbing
Roll Grinding
Form Grinding
Honing
Lapping
Gear Materials and Tasks
Material properties
High tensile strength to prevent failure against static loads
High endurance strength to withstand dynamic loads
Low coefficient of friction
Good manufacturability

Materials used for gears
Steel
Stainless Steel
High Carbon Steel Alloys
Cast Iron
Bronze Alloys
Brass
Aluminum
Plastic
...

Gear tasks:
Change the speed
Change the torque
Change the direction of the rotation
Join shafts with centre distance
Join shafts with different angles
Output
scalping wheel with 60 tooth
2.000 revolutions per minute
120.000 cuts per minute
high number of cuts per timeunit
very short machining time
high toothing quality
small surface roughness (Rz 1-5 µm)
Input
Manual with indexing head
the hob
a helical cutting tool
CNC milling
Skiving will more and more prevail due the fact that it is up to 6 times faster that hobbing
5-axis-gear milling will catch on because CNCs are getting faster and precise (abandonment of special tools and machines)
manufacture products in one clamping (less changeover costs)
Full transcript