S.H.

JONDHALE POLYTHENIC OF ENGINEERING DOMBIVILI (W)

A
PROJECT REPORT ON
GEAR MANUFACTURING
FOR THE COUSRE
ADVANCED MANUFACTURING PROCESSES (22563)
SUBMITTED BY-
NAME
NAMESH KORKE
NIKHIL MEMANE
SUMMET THAKRE
PRATIK KHANDEWAL
ROHAN AVHAD
GUDIED BY-
PROF.AVIRAJ
SUBMITTED TO-
S.H.JONDHALE DOM
 ABSTRACT

Gear manufacturing plays a pivotal role in various

industries, including automotive, aerospace, and
robotics. This abstract highlights recent advancements in
gear manufacturing techniques and technologies, with a
focus on precision engineering, enhanced efficiency, and
sustainable practices. We delve into the evolution of gear
manufacturing methods, including traditional hobbing
and shaping processes, as well as cutting-edge
techniques such as additive manufacturing and advanced
materials. Additionally, we explore the integration of
digitalization and automation to optimize gear
production processes. Furthermore, this abstract
discusses the importance of sustainability in gear
manufacturing, emphasizing reduced waste, energy
efficiency, and environmentally friendly materials. These
innovations collectively contribute to the evolution of
gear manufacturing, enabling industries to meet the
demands of modern applications while minimizing
environmental impact.
 MAHARASHTRA STATE BOARD OF
TECHNICAL EDUCATION
Certificate
This is to certify that Mr. Namesh korke,Nikhil
memane,sumeet thakre,pratik khabdewal,rohan
avhad of T. Y. M. E Semester of Diploma in
Mechanical Engineering of Institute, S. H. Jondhale
Polytechnic (Code: 0044) has completed the Micro
Project satisfactorily in Subjet:-MANUFACTURING
PROCESS(22563) for the academic year 2023- 2024
as prescribed in the curriculum.

PLACE- DOMBIVILI DATE-

TEACHER HEAD OF DEPARTMENT PRINCIPAL

 ACKNOWLEDGMENT

We wish to express our gratitude to all those who contributed

to the completion of this gear manufacturing report.

We extend our appreciation to our team members for their

dedication and hard work in gathering and analyzing data.

We also acknowledge the valuable support and guidance

provided by our mentors and industry experts throughout this
project.

Lastly, we thank our families and friends for their

understanding and encouragement during this endeavor.
 CONTENTS

SR.NO Name of context

1. INTRODUCTION
2. TYPES OF GEARS
3. MANUFACTURING PROCESS
4. MATERIALS USED
5. DESIGN CONSIDERATIONS
6. INSPECTION AND QUALITY CONTROL
7. CONCLUSION
 INTRODUCTION

Background and Importance of Gear Manufacturing

Gear manufacturing is a critical process in the production of machinery

and mechanical systems. Gears are mechanical components with toothed
surfaces designed to transmit motion and power between rotating shafts
efficiently. The background and importance of gear manufacturing can
be outlined as follows:

1. Historical Significance: The concept of gears dates back to ancient

civilizations like the Greeks and Egyptians, who used simple gears in
devices such as watermills. Over centuries, gear technology has evolved
significantly, contributing to the development of modern machinery.

2. Industrial Revolution: The Industrial Revolution marked a turning

point in gear manufacturing. Gears became fundamental components in
machines like textile mills, locomotives, and factories, driving
industrialization and economic growth.

3. Modern Machinery: In the contemporary era, gear manufacturing

plays a pivotal role in a wide range of applications, from automobiles to
aerospace, robotics, and renewable energy systems. Without gears, the
complex machinery we rely on today would not function efficiently.
4. Efficiency and Power Transmission: Gears are crucial for the
efficient transmission of power and motion. They allow for speed
reduction or amplification, torque multiplication, and directional
changes in machinery, ensuring optimal performance.

5. Diverse Industries: Gear manufacturing serves various industries,

including automotive, aerospace, mining, construction, healthcare
(medical devices), and more. Each industry has specific gear
requirements tailored to their applications.

6. Safety and Reliability: Properly manufactured gears are essential for

the safety and reliability of machinery. Gears must meet stringent quality
standards to prevent failures that could lead to accidents and downtime.

Objectives of the Report:

 The objectives of the report on gear manufacturing are as follows:

1. Educational Purpose: To provide a comprehensive and educational

resource on gear manufacturing, catering to students, engineers, and
professionals interested in understanding the intricacies of gears.

2. Industry Insights: To offer insights into the various gear types,

manufacturing processes, materials, and design considerations relevant
to different industries. This knowledge can assist manufacturers and
engineers in selecting the right gears for their applications.

3. Quality and Efficiency: To emphasize the importance of quality

control, heat treatment, lubrication, and gear inspection in ensuring the
durability, efficiency, and safety of gears in machinery.

4. Environmental Awareness: To address the environmental impact of

gear manufacturing processes and promote sustainable practices,
aligning with contemporary concerns for ecological sustainability.

5. Technological Advancements: To highlight recent advancements in

gear manufacturing technology, including automation, robotics, and
digitalization, and their potential to reshape the industry.

TYPES OF GEAR
1. Spur Gears:
 1. Description: Spur gears are the most common type of gear with
straight teeth that are parallel to the gear axis. They provide a
simple and cost-effective way to transmit motion and power.

2. Applications: Spur gears are utilized in a wide range of machinery,

including gear pumps, electric screwdrivers, wind-up alarm clocks,
and conveyor systems. They are ideal for applications where
precision and noise are not critical factors.

2. Helical Gears:
1. Description: Helical gears have teeth that are cut at an angle to
the gear axis, forming a helix shape. This design offers smoother
and quieter operation compared to spur gears due to the gradual
engagement of teeth.

2. Applications: Helical gears are essential in industries requiring

high precision and reduced noise, such as automotive
transmissions, printing presses, textile machinery, and robotics.
Their ability to handle higher loads and transmit motion
smoothly makes them invaluable in these applications.

SPUR GEAR
 HELICAL GEAR

3. Bevel Gears:
 1. Description: Bevel gears have teeth that are cut on a cone-shaped
surface, allowing them to transmit motion between intersecting
shafts at various angles.

2. Applications: Bevel gears are commonly found in differential

gear systems in automobiles, where they transfer power from the
driveshaft to the wheels. They are also used in hand drills to
change the direction of rotation and in marine propulsion systems
to transfer power from the engine to the propeller shaft.

4. Worm Gears:
1. Description: Worm gears consist of a spiral thread (the worm) that
meshes with a toothed wheel (the worm gear). This unique
configuration provides high gear reduction ratios and excellent
self-locking capabilities.

2. Applications: Worm gears are prevalent in applications where

high gear reduction is necessary, such as in lifts and hoists. They
are also used in conveyor systems, winches, and some valve
actuators due to their ability to hold a load in position without
backdriving.

BEVEL GEAR
 WORM GEAR

5. Rack and Pinion Gears:

 1. Description: Rack and pinion gears involve a linear gear (the
rack) that meshes with a rotating gear (the pinion). This
configuration is used for converting rotational motion into linear
motion or vice versa.

2. Applications: Rack and pinion gears are common in steering

systems of automobiles, CNC machines for precise linear
movement, and linear actuation systems in robotics. They are
chosen for applications that require efficient conversion between
rotary and linear motion.

1. Hobbing
Description:
 Hobbing is a widely employed gear manufacturing process used to
produce cylindrical gears. It relies on a specialized cutting tool known as
a hob, which has a series of teeth that progressively engage with the
workpiece to form gear teeth.
Process:
The workpiece, often a gear blank, is securely mounted on a hobbing
machine.
i. Both the hob and the workpiece rotate simultaneously.
ii. As the hob moves axially across the rotating workpiece, it
incrementally removes material to create gear teeth.
iii. Hobbing can generate various types of gears, including spur gears,
helical gears, and worm gears.

Advantages:
i. Hobbing provides high accuracy and repeatability.
ii. It is well-suited for mass production due to its efficiency.
iii. This process yields a good surface finish.
iv. Hobbing is versatile, accommodating various gear types.

Disadvantages:
i. Hobbing can be relatively slower compared to some other
manufacturing methods.
ii. It necessitates a specialized hobbing machine.

2. Shaping
Description: Shaping is a gear cutting process that employs a shaping
cutter with teeth resembling the inverse tooth profile of the desired gear.
Process:
 i. The workpiece is clamped onto a shaping machine.
ii. The shaping cutter moves in a reciprocating motion, cutting one
tooth space at a time.
iii. The workpiece is indexed to cut each tooth, typically in an
incremental manner.
iv. Shaping is primarily used for creating internal and external spur
gears.

Advantages:
i. Shaping offers the advantage of equipment simplicity.
ii. It is suitable for small production runs.
iii. This method is well-suited for prototyping and crafting custom
gears.

Disadvantages:
i. Shaping can be slower than other processes, particularly for mass
production.
ii. Its application is largely limited to certain gear types, primarily
spur gears.

3. Gear Grinding:

Description: Gear grinding is a precision machining process used to

achieve exceptional accuracy and surface finish in gears. It is often
employed after gear cutting processes such as hobbing or shaping.
Process:
 i. Gear grinding employs specialized grinding machines equipped
with abrasive grinding wheels.
ii. The gear and grinding wheel rotate in opposite directions.
iii. The grinding wheel removes material incrementally, resulting in
precise tooth profiles.
iv. Gear grinding is capable of achieving high-precision, high-quality
gear finishing.

Advantages:
i. Gear grinding provides unparalleled accuracy and surface finish,
making it suitable for critical applications with tight tolerances.
ii. It can achieve exceptionally tight tolerances.
iii. Gear grinding is suitable for hardened gears, enhancing their
longevity due to improved surface quality.

Disadvantages:
i. Gear grinding requires specialized grinding machines, leading to
higher tooling and operational costs.
ii. It can be slower compared to other processes, impacting
production rates.

Accuracy and Precision:

i. Gear Grinding: Gear grinding stands out for its exceptional
accuracy and precision. It is the preferred choice for applications
demanding the highest level of dimensional accuracy and tight
tolerances. Gear grinding ensures that gear teeth conform
precisely to the desired specifications, reducing the risk of
performance issues or failures.

ii. Hobbing and Shaping: While hobbing and shaping are accurate
processes, they may have slightly lower precision compared to
 gear grinding. The incremental material removal in these methods
can result in gear teeth profiles that are very close to the desired
specifications but may require additional inspection and
adjustments for ultra-precise applications.

Surface Finish:
i. Gear Grinding: Gear grinding achieves the finest surface finish
due to its abrasive nature. The grinding process removes small
imperfections, resulting in smooth and polished gear teeth
surfaces. This enhanced surface finish not only contributes to
superior performance but also reduces wear and noise, making it
ideal for demanding applications.

ii. Hobbing and Shaping: Hobbing and shaping can produce good
surface finishes but may not achieve the same level of smoothness
as gear grinding. In some cases, post-processing operations like
honing or lapping may be necessary to achieve an exceptional
surface finish, especially for critical applications.

Versatility:
Hobbing: Hobbing is renowned for its versatility and capability to
produce various gear types, including spur gears, helical gears, and
worm gears. This adaptability makes it a preferred choice in industries
with diverse gear requirements, providing manufacturers with the
flexibility to meet a wide range of application needs.
i. Shaping: Shaping is primarily limited to the production of spur
gears. While it may not offer the same versatility as hobbing, it is
effective for creating internal and external spur gears.
 ii. Gear Grinding: Gear grinding is often employed as a finishing
process, adding precision and surface quality to gears produced
through hobbing or shaping. It is not a primary method for creating
gears but plays a crucial role in achieving the desired gear
characteristics.

Production Rate:
i. Hobbing: Hobbing is the fastest among these processes, making it
well-suited for mass production scenarios. Its efficiency and ability
to produce a large number of gears in a relatively short time make
it a cost-effective choice for high-volume manufacturing.

ii. Shaping: Shaping is slower compared to hobbing, making it

suitable for small to medium production runs or when specialized
spur gears are required.

iii. Gear Grinding: Gear grinding is the slowest of the three methods,
mainly due to the precision and meticulous nature of the process. It
is typically used for finishing and achieving exceptional accuracy
rather than high-speed production.

Tooling and Equipment:

i. Hobbing: Hobbing requires specialized cutting tools (hobs) and
dedicated hobbing machines. The tooling and equipment are
designed to accommodate a wide range of gear types and sizes.

ii. Shaping: Shaping relies on shaping cutters and shaping machines.

While the equipment is relatively simpler, it is tailored primarily to
spur gear production.
iii. Gear Grinding: Gear grinding necessitates specialized grinding
machines with abrasive grinding wheels designed for precision.
These machines are dedicated to achieving superior surface quality
and accuracy.

In conclusion, the choice of a gear manufacturing process should

consider factors such as required precision, surface finish, production
volume, gear type, and cost. Hobbing is efficient for mass production
and versatile in gear type production, shaping is suitable for smaller runs
and specific spur gears, while gear grinding excels in precision and
surface finish, but at a slower rate and higher cost. Selecting the right
process is essential to meet the specific needs of each application.

Materials Used in Gear Manufacturing:

Gear manufacturing employs a variety of materials, each selected based

on specific application requirements. Common materials used in gear
manufacturing include:

1. Steel Alloys:
- Carbon Steel: Offers good strength and durability. Often used for low
to moderate load applications.
 - Alloy Steel: Contains additional alloying elements like chromium,
molybdenum, and nickel for enhanced strength, wear resistance, and
toughness.
- Stainless Steel: Known for its corrosion resistance, making it suitable
for applications in harsh environments.

2. Cast Iron:
- Gray Cast Iron: Provides good wear resistance and is often used for
low-speed and low-load applications.
- Ductile Cast Iron: Offers higher strength and ductility compared to
gray cast iron, making it suitable for higher-load situations.

3. Bronze and Brass Alloys:

-Phosphor Bronze: Exhibits excellent wear resistance and is often used
in low-speed, high-load applications.
- Brass: Known for its low friction properties and is used in
applications where noise reduction is important.

4. Plastics:
- Nylon: Offers good wear resistance and low friction properties.
Commonly used in applications where quiet operation is crucial, such as
in consumer products.
 - Acetal (Delrin): Known for its excellent dimensional stability and
resistance to moisture absorption.

5. Aluminum and Aluminum Alloys:

- Aluminum Bronze: Combines the properties of aluminum and
bronze, offering good corrosion resistance and moderate strength.
- 6061-T6 Aluminum Alloy: Provides a balance of strength and
weight, suitable for lightweight gear applications.

Material Selection Criteria:

When selecting a material for gear manufacturing, several factors should

be considered:

1. Load and Stress: Determine the magnitude of the loads and stresses
the gear will experience. Higher loads require materials with greater
strength and toughness.

2. Speed: Consider the rotational speed of the gear, as high-speed

applications may require materials with excellent wear resistance and
low friction to reduce heat generation.
3. Wear Resistance: Evaluate the wear resistance of the material,
especially in applications with continuous motion. Harder materials are
often preferred for wear-prone situations.

4. Corrosion Resistance: For gears exposed to moisture or corrosive

environments, materials with good corrosion resistance, such as stainless
steel or specific alloys, are essential.

5. Noise and Vibration: Some applications require gears to operate

quietly. Materials like nylon or acetal, which reduce noise and vibration,
are suitable choices.

6. Cost: Consider the cost of materials and manufacturing processes.

High-performance materials may come at a higher cost.

7. Manufacturability: Assess whether the selected material is easy to

machine, forge, or cast, depending on the manufacturing method chosen.

8. Operating Temperature: Gears operating at extreme temperatures may

require materials that can maintain their properties under such
conditions.

9. Dimensional Stability: Evaluate the material's ability to maintain

precise dimensions over time, especially in high-precision applications.
10. Environmental Impact: Consider environmental concerns and
regulations when selecting materials, especially in industries with strict
sustainability requirements.

The choice of gear material should align with the specific demands of
the application, ensuring optimal performance, durability, and reliability
while considering factors such as load, speed, wear resistance, and cost.

1. Design Considerations:

Gear Design Fundamentals:

- Gear design is a complex process that involves determining the tooth
profile, size, and specifications of gears to achieve specific motion,
speed, and torque requirements.

- Essential parameters include the gear module (size of the gear teeth),
pitch diameter, number of teeth, pressure angle, and helix angle (for
helical gears).

- Gear ratios are crucial for defining the speed and torque relationship
between gears in a system, impacting overall system performance.
- Contact patterns, backlash (the space between gear teeth), and tooth
root fillets (smooth transitions at tooth roots) are considered to ensure
smooth and efficient gear operation, minimizing wear and noise.

Tolerances and Standards:

- Gear design must adhere to industry standards and tolerances to ensure
compatibility and interchangeability of gears in different systems.

- Organizations like the AGMA (American Gear Manufacturers

Association) provide comprehensive standards for gear design,
manufacturing, and inspection.

- Tolerances define allowable variations in gear dimensions, tooth

profiles, and other critical parameters. Precise tolerancing is crucial for
reliable gear operation.

- ISO standards provide guidelines for gear accuracy and quality on a

global scale, facilitating international gear trade and ensuring uniformity
in gear manufacturing practices.
- GD&T (Geometric Dimensioning and Tolerancing) is often used to
specify tolerances and ensure precise gear manufacturing by defining
permissible variations in form, orientation, location, and profile.

2. Gear Inspection and Quality Control:

Methods for Inspecting Gears:

- Visual Inspection: Visual examination is the initial step in the

inspection process, where inspectors look for visible defects such as
chipping, pitting, surface irregularities, or misalignment.
- Dimensional Inspection: Precise measurements are essential to ensure
that gear dimensions meet design specifications. Tools like micrometers,
calipers, and coordinate measuring machines (CMMs) are used to verify
critical dimensions.
- Profile Testing: Profile testing checks the gear tooth profile for
accuracy, ensuring that the actual tooth shape matches the design. Gear
measuring machines are commonly used for this purpose.
- Runout Testing: Runout tests verify the gear's axial and radial
alignment by measuring deviations from a perfect circle during rotation.
Accurate alignment is crucial for smooth gear operation.
- Surface Roughness Measurement: Surface finish is critical to reduce
friction and wear in gears. Instruments like profilometers measure
surface roughness to ensure it meets specified requirements.
- Gear Testing Machines: Specialized gear testing machines analyze
various parameters, including tooth contact pattern, backlash (tooth
clearance), and tooth lead deviation, providing detailed insights into gear
performance and quality.

Quality Control Techniques:

- Statistical Process Control (SPC): SPC is a data-driven approach that

monitors and controls the manufacturing process using statistical
methods. It helps ensure that gear production remains within specified
tolerances, reducing defects and variations.

- Six Sigma: Six Sigma is a comprehensive methodology aimed at

minimizing defects and variations in gear manufacturing processes. It
involves data analysis, process improvement, and rigorous problem-
solving techniques.

- Root Cause Analysis: When defects are detected, root cause analysis is
performed to identify the underlying reasons. Understanding the root
causes allows for corrective actions to prevent similar issues in the
future.
- Failure Mode and Effects Analysis (FMEA): FMEA assesses potential
failure modes and their impact on gear performance and reliability. It
enables preemptive quality improvements to prevent failures.

- ISO Certification: Many manufacturers pursue ISO 9001 certification

to demonstrate adherence to international quality management standards.
Certification enhances customer confidence in the quality of products.
- Non-Destructive Testing (NDT): NDT techniques like magnetic
particle testing or ultrasonic testing can detect hidden defects in gears
without damaging them, providing an added layer of quality assurance.

- In-Process Inspection: Inspection steps integrated into the

manufacturing process identify and rectify defects early, reducing waste,
rework, and production costs.

Effective quality control ensures that manufactured gears meet design

specifications, function reliably, and have long service lives. It also
helps identify and mitigate defects early in the manufacturing process,
reducing waste and costs while improving overall product quality and
customer satisfaction.
 Conclusion
conclusion, the gear manufacturing process is a critical and
precise operation essential for various industries, including
automotive, aerospace, and machinery. It involves several
methods such as machining, forging, and casting, each with its
advantages and applications. The choice of method depends on
factors like material, production volume, and gear specifications.
Precision and quality control are paramount throughout the
process to ensure the gears meet design specifications and
function efficiently. Continuous advancements in technology
and materials are likely to further enhance gear manufacturing
processes, making them even more crucial in modern
manufacturing.
THANK YOU