Modern Academy for Engineering and Technology

Modern Academy for Engineering and

Technology
Mechanical Engineering
Manufacturing and production
Technical Report Writing GENn142a-
GR14Y20-F
Gear Manufacturing
Summitted to: Dr/ Sally Saad El-Din
Submitted by: Malak Ahmed Ali
4230003
Date : 21/11/2023
Modern Academy for Engineering and Technology

content
Table of Contents
Summary……………………………………………………………………………………………………………………..……..….ii
1.0 Introduction.......................................................................................................................... 5
2.0 Spur gear .............................................................................................................................. 6
2.1 Spur geardesign................................................................................................................. 6
2.2 spur gear relation ship…………….…………………………..………………….…………………………………...7
2.3 Spur gear is made :............................................................................................................8
2.4 Types of spur gear.............................................................................................................12
2.5 Spur Gear Materials ...................................................................................................14
3.0 Helical gear ...........................................................................................................................16
3.1 Helical gear design.........................................................................................................16
3.2 Helical gear relation ship……..……………………………………………………………..…………………...17
3.3 Helical gear is made .....................................................................................................18
3.4 Types of helical gear.....................................................................................................22
4.0 Worm gear ............................................................................................................................24
4.1 Worm gear design ........................................................................................................24
4.2 Worm gear is made:-....................................................................................................25
5.0 Conclusion .............................................................................................................................26
6.0 References.............................................................................................................................. 27
Modern Academy for Engineering and Technology

Summary

Gear manufacturing is the process of creating gears, which are

mechanical components that transmit power between rotating
shafts. The production process usually involves cutting, shaping,
and finishing raw materials such as metal or plastic to achieve
the desired gear profile. Gear manufacturing techniques include
gear hobbing, gear shaping, gear grinding, and gear milling.
Gears must be manufactured with precise tolerances and
quality control measures to ensure their performance. With the
advancement of technology and automation, gear
manufacturing processes have become more efficient and
accurate

4
Modern Academy for Engineering and Technology

1.0 Introduction

Gear manufacturing is the process of creating gears, which are

mechanical components used to transmit torque and power
between two rotating shafts. Gears can be found in a wide
range of machines and mechanical devices, from automobiles
and airplanes to industrial equipment and household
appliances. Gear manufacturing is a critical process in various
industries, as gears play a vital role in the performance and
functionality of many machines and systems. For example: 
Automotive Industry  Aerospace Industry  Manufacturing
Industry  Mining Industry  Energy Industry Gear
manufacturing is essential for creating high-quality, reliable,
and efficient machines and systems in various industries.
Without gears, many machines and systems would not be able
to function properly, leading to reduced productivity, increased
costs, and potential safety hazards

5
Modern Academy for Engineering and Technology

2.0 Spur gear

A spur gear is a cylindrical toothed gear with teeth that are

parallel to the shaft and is used to transfer mechanical motion
and control speed, power, and torque between shafts. They are
the most popular types of cylindrical gears and have a simple
design of straight parallel teeth positioned equally around the
circumference of the cylinder barrel.
Spur gear design

6
Modern Academy for Engineering and Technology

2.1 Spur gear is made:

1. Design the gear: The first step in making a spur gear is to design it using specialized software
or by manually calculating the gear parameters. This includes determining the gear pitch,
number of teeth, pressure angle, and other specifications.
2. Choose the hob: Select the hob that matches the desired gear specifications. The hob should
have the same pitch, pressure angle, and number of teeth as the gear to be made.
3. Mount the workpiece: Mount the workpiece onto the hobbing machine's spindle. The
workpiece should be centered and secured tightly to prevent movement during the hobbing
process.
4. Set up the hob: Mount the hob onto the hobbing machine's hob arbor. The hob should be
positioned so that it can make contact with the workpiece and rotate in the correct direction.
5. Adjust the machine settings: Adjust the machine's settings to match the gear specifications,
including the hob position, speed, and feed rate.
6. Start the hobbing process: Start the hobbing machine and gradually move the hob into
contact with the workpiece. The hob will rotate and cut into the workpiece, producing the gear
teeth. The hobbing machine's table will also move to create the correct gear tooth profile
7. Finish the gear: Once the gear teeth are cut, the gear will need to be finished to remove any
burrs or rough edges. This can be done using a deburring tool or by polishing the gear teeth.
8. Test the gear: Finally, the gear should be tested to ensure that it meets the desired
specifications. This can be done using specialized gear testing

7
Modern Academy for Engineering and Technology

1. Design the gear: The first step in making a spur gear is to design it using specialized software
or by manually calculating the gear parameters. This includes determining the gear pitch,
number of teeth, pressure angle, and other specifications.
2. Choose the shaping tool: Select the shaping tool that matches the desired gear specifications.
The tool should have the same pitch, pressure angle, and number of teeth as the gear tobe
made.
3. Mount the workpiece: Mount the workpiece onto the shaping machine's table. The
workpiece should be centered and secured tightly to prevent movement during the shaping
process.
4. Set up the shaping tool: Mount the shaping tool onto the shaping machine's ram. The tool
should be positioned so that it can make contact with the workpiece and move in the correct
direction.
5. Adjust the machine settings: Adjust the machine's settings to match the gear specifications,
including the tool position, speed, and feed rate.
6. Start the shaping process: Start the shaping machine and gradually move the tool into contact
with the workpiece. The tool will move back and forth to cut into the workpiece, producing the
gear teeth.
7. Finish the gear: Once the gear teeth are cut, the gear will need to be finished to remove
any burrs or rough edges. This can be done using a deburring tool or by polishing the gear teeth
8. Test the gear: Finally, the gear should be tested to ensure that it meets
thedesiredspecifications. This can be done using specialized gear testing equipment

8
Modern Academy for Engineering and Technology

1. Choose the material: Select the appropriate cold drawn steel material for the gear. The
material should have the necessary strength and durability for the application.
2. Prepare the steel: The cold drawn steel should be processed to the appropriate size and
shape.
This may involve cutting or shearing the steel, followed by heating and forging it into the desired
shape.
3. Cut the blank: Cut a blank of cold drawn steel to the size and shape required for the gear.
4. Rough cut the gear teeth: Use a specialized cutting tool, such as a gear shaper or hob, to
rough cut the gear teeth into the blank.
5. Heat treat the gear: Heat treat the gear to harden the steel and increase its durability.
The heat treatment process will depend on the specific type of cold drawn steel being used.
6. Finish the gear teeth: Use a finishing tool, such as a grinding wheel or honing stone, to
smooth and shape the gear teeth to the desired profile and finish.
7. Inspect the gear: Inspect the gear to ensure that it meets the required specifications,
including tooth profile, pitch, and surface finish

9
Modern Academy for Engineering and Technology

1. Design the gear: The first step in making a spur gear is to design it using specialized
software or by manually calculating the gear parameters. This includes determining the
gear pitch, number of teeth, pressure angle, and other specifications
2. Prepare the material: Prepare the material that will be used to make the gear. This can be a
strip of metal, plastic or other material that is fed into the roll forming machine
3. Set up the roll forming machine: Set up the roll forming machine with the correct
number of rollers and tooling to match the gear specifications. The rollers will shape the
material into the desired gear tooth profile.
4. Feed the material into the machine: Feed the material into the roll forming machine, ensuring
that it is positioned correctly and securely.
5. Form the gear teeth: As the material moves through the roll forming machine, the rollers will
shape it into the desired gear tooth profile. The gear teeth will be gradually formed as the
material passes through each set of rollers.
6. Cut the gear: Once the gear teeth are formed, the material will need to be cut into the
desired shape. This can be done using a specialized cutting tool or by punching the gear out of
the material.
7. Inspect the gear: Inspect the gear to ensure that it meets the required specifications,
including tooth profile, pitch, and surface finish

10
Modern Academy for Engineering and Technology

1. Design the gear: The first step in making a spur gear is to design it using specialized

software or by manually calculating the gear parameters. This includes determining the

gear pitch, number of teeth, pressure angle, and other specifications.

2. Choose the material: Select the appropriate material for the gear. Common materials

used for forging gears include steel, titanium, and brass.

3. Heat the material: Heat the material in a forge until it reaches the necessary

temperature for forging. The specific temperature will depend on the type of material

being used.

4. Form the gear: Use a die set to form the heated material into the desired gear shape.

The die set will include a male and female die, which will shape the material into the

gear profile. The male die will have the inverse of the gear tooth profile, while the

female die will have the gear tooth profile.

5. Finish the gear: Once the gear is formed, it may need to be finished using specialized

tools to achieve the desired surface finish and tooth profile.

6. Heat treat the gear: Heat treat the gear to harden the material and increase its

durability. The heat treatment process will depend on the specific type of material being

used.

7. Inspect the gear: Inspect the gear to ensure that it meets the required specifications,

including tooth profile, pitch, and surface finish

11
Modern Academy for Engineering and Technology

2.2 Types of spur gear

The configuration of an external spur gear is typical of
all types of gears with the teeth of the gear on the
cylinder’s surface. When it meshes with another gear,
the gears will rotate in the opposite direction.

inner The teeth for an internal spur gear are cut on

the surface of the gear. The external surface is
smooth in the shape of a perfect oval or circle. The
inner gear teeth mesh with a pinion or smaller gear.
The gears rotate in the same direction

A pin hub spur gear has a set screw used to

secure a pin on the gear to the shaft. They can
be connected to a shaft using a dowel, spring,
roll, or taper pins. The hole in the gear is drilled
to the exact size of the pin for a tight
connection. The set screw used to pin the gear
to the shaft is removed to avoid loosening
and falling into the mechanis

12
Modern Academy for Engineering and Technology

With a keyway spur gear, a slot is cut in the gear’s

bore that fits the slot milled into the shaft. The
keyway allows the shaft and gear to fit snugly
together with the proper alignment of the slots.
The purpose of the design is to eliminate slippage
between the shaft and spur gear

The positive characteristics of plastic gears are their

lightweight, high rust resistance, silent operation, low
cost, and the ability to operate without lubrication.
They are very durable, strong, and reliable and can
easily be interchanged. Plastic spur gears are the
most common form of plastic gear

Set screw spur gears can have a keyed or round bore with
a set screw in their hub that attaches them to the shaft
through the hub. They work like pin hub spur gears,
except that the set screw is not removed. Set screw spur
gears allow for a certain amount of flexibility in placing
the gear and provide a secure tight fit

13
Modern Academy for Engineering and Technology

2.3 Spur Gear Materials

Aluminum alloys are used to make spur gears for
applications that need a high strength to weight
ratio since aluminum is one third the weight of
steel and has a surface that is resistant to
corrosion. It is more expensive than steel but less
expensive than stainless steel. Aluminum alloys are
easy to machine, which offsets its higher cost.

Steel is an alloy of iron, carbon, and various other

elements. There are four major steel types: carbon,
alloy, stainless, and tool steel. Of the various types,
carbon steel is used the most to manufacture spur gears
because it is easy to machine, is wear resistant, able to
be hardened, available, and inexpensive

can be molded into any shape and is resistant to rust.

The composition of cast iron involves the use of
different ingredients each of which gives cast iron a
different degree of strength and durability. Cast iron
is commonly used to produce machine parts because
of its low cost, rust resistance, and ability to be easily
molded and shaped. It can be unbelievably strong or
very weak, depending on the types of added
mixtures

14
Modern Academy for Engineering and Technology

Stainless steel comes in several levels, grades, and

characteristics, with all types having at least 11%
chromium. Other alloys include nickel, manganese,
silicon, phosphorus, sulfur, and nitrogen. Ferritic
stainless steels are magnetic, while austenitic stainless
steels are nonmagnetic, martensitic, and precipitation
hardened

There are several types of plastics used to produce

plastic spur gears, including polyacetal, nylon,
polyethylene, and polyetheretherketone ,a ketone
polymer. Plastic spur gears are lightweight, rust
resistant, inexpensive to produce, and can operate
without producing friction. They are widely used in
food production, electronics, toys, and medical
instruments.

15
Modern Academy for Engineering and Technology

3.0 Helical gear

Helical gears are cylindrical gears with teeth bent into a helix shape; these teeth
are positioned at an angle to the gear axis called the helix angle. A helical gear has
the same involute tooth geometry as a spur gear in section view, despite being
cut. With proper design, the larger overall contact ratio in helical gears can reduce
vibration and noise. Helical gears feature stronger teeth and a higher load-carrying
capability than spur gears. With a high degree of component and sub-assembly
interchangeability, the modular design and fabrication of helical gears in
gearboxes offer several engineering and performance benefits. This provides for
costeffective construction while maintaining the highest level of component
integri

3.1 Helical gear design

16
Modern Academy for Engineering and Technology

3.2 Relationships used in the manufacture of the

helical gear:-

Name Relation
Pitch Circle Diameter D = m Z=(mn/cos Ψ)* Z
Addendum Of Gear Da= D +2a=D+2mn
Dedendum Of Gear Dd= D – 2d=D-2.5mn
Face width B= (3-5) PC or (10-15)mn
Hub length Lh = (1-1.4)B
Hub Diameter Dh = (1.5-2) Dshaft
Web Thickness Tw = Pc

17
Modern Academy for Engineering and Technology

3.3 Helical gear is made

1. Prepare the hobbing machine: Before you start, you need to make sure that the hobbing machine is
properly set up and calibrated for the type of gear you want to make. This

includes installing the correct hob, setting the proper cutting parameters, and adjusting the machine's
feed and speed.

2. Mount the workpiece: The workpiece is the metal blank that will be cut into a gear. It

needs to be securely mounted on the hobbing machine's spindle so that it can rotate freely during the
cutting process.

3. Align the hob and the workpiece: The hob is the cutting tool that will be used to create the gear teeth.
It needs to be properly aligned with the workpiece so that it can cut the

teeth at the correct angle and depth. This is done by adjusting the position of the hob relative to the
workpiece using the machine's controls.

4. Start the cutting process: Once the hob and workpiece are properly aligned, you can

begin the cutting process. The hob will rotate and move slowly across the face of the

workpiece, gradually cutting away the metal to create the gear teeth. The cutting process can take
anywhere from a few minutes to several hours, depending on the size and complexity of the gear.

5. Check the gear for accuracy: Once the cutting process is complete, you'll need to check the gear to
make sure it meets the required specifications for accuracy and quality. This may involve measuring the
gear's dimensions, inspecting the teeth for defects or irregularities, and performing other tests as
needed.

6. Finish the gear: Depending on the application, you may need to perform additional operations to
finish the gear, such as heat treating, grinding, or polishing

18
Modern Academy for Engineering and Technology

1. Prepare the broaching machine: Before you start, you need to make sure that the broaching
machine is properly set up and calibrated for the type of gear you want to make. This includes
installing the correct broaching tool, setting the proper cutting parameters, and adjusting the
machine's feed and speed.
2. Mount the workpiece: The workpiece is the metal blank that will be cut into a gear. It
needs to be securely mounted on the broaching machine's fixture so that it can be held firmly
during the cutting process
3. Align the broaching tool and the workpiece: The broaching tool is the cutting tool that
will be used to create the gear teeth. It needs to be properly aligned with the workpiece
so that it can cut the teeth at the correct angle and depth. This is done by adjusting the
position of the tool relative to the workpiece using the machine's controls.
4. Start the cutting process: Once the broaching tool and workpiece are properly aligned,
you can begin the cutting process. The broaching tool will move slowly across the face of
the workpiece, gradually cutting away the metal to create the gear teeth. The cutting process
can take anywhere from a few minutes to several hours, depending on the size and complexity
of the gear.
5. Check the gear for accuracy: Once the cutting process is complete, you'll need to check the
gear to make sure it meets the required specifications for accuracy and quality. This may involve
measuring the gear's dimensions, inspecting the teeth for defects or irregularities, and
performing other tests as needed.
6. Finish the gear: Depending on the application, you may need to perform additional
operations to finish the gear, such as heat treating, grinding, or polishing.

19
Modern Academy for Engineering and Technology

1. Mount the workpiece: The workpiece is the metal blank that will be cut into a gear. It needs
to be securely mounted on the gear shaping machine's fixture so that it can be held firmly
during the cutting process.
2. Install the cutting tool: The cutting tool used in a gear shaping machine is called a shaper
cutter, which has teeth arranged in a helical pattern. The cutter needs to be properly installed in
the machine and aligned with the workpiece before the cutting process begins.
3. Set the cutting parameters: The cutting parameters for a gear shaping machine will vary
depending on the specific requirements of the gear being produced. This includes parameters
such as the feed rate, cutting speed, and depth of cut.
4. Start the cutting process: Once the cutting parameters are set, the gear shaping
machine can begin the cutting process. The shaper cutter will move across the face of
the workpiece, gradually cutting away the metal to create the gear teeth. As the cutter
moves across the workpiece, it will also rotate slightly to create the helical tooth profile.
5. Check the gear for accuracy: Once the cutting process is complete, you'll need to check
the gear to make sure it meets the required specifications for accuracy and quality. This
may involve measuring the gear's dimensions, inspecting the teeth for defects or irregularities,
and performing other tests as needed.
6. Finish the gear: Depending on the application, you may need to perform additional
operations to finish the gear, such as heat treating, grinding, or polishing

20
Modern Academy for Engineering and Technology

1. Mount the workpiece: The workpiece is the metal blank that will be cut into a gear. It needs
to be securely mounted on the gear grinding machine's fixture so that it can be held firmly
during the grinding process.
2. Install the grinding wheel: The grinding wheel used in a gear grinding machine is specially
designed to produce the precise shape and finish needed for helical gears. It needs to be
properly installed in the machine and aligned with the workpiece before the grinding process
begins.
3. Set the grinding parameters: The grinding parameters for a gear grinding machine will vary
depending on the specific requirements of the gear being produced. This includes parameters
such as the grinding depth, grinding speed, and dressing frequency.
4. Start the grinding process: Once the grinding parameters are set, the gear grinding machine
can begin the grinding process. The grinding wheel will move across the face of the workpiece,
gradually removing small amounts of metal to create the helical tooth profile. As the wheel
moves across the workpiece, it will also rotate slightly to create the helical tooth angle.
5. Check the gear for accuracy: Once the grinding process is complete, you'll need to check the
gear to make sure it meets the required specifications for accuracy and quality. This may involve
measuring the gear's dimensions, inspecting the teeth for defects or irregularities, and
performing other tests as needed.
6. Check the gear for accuracy: Once the grinding process is complete, you'll need to check the
gear to make sure it meets the required specifications for accuracy and quality. This may involve
measuring the gear's dimensions, inspecting the teeth for defects or irregularities, and
performing other tests as needed

21
Modern Academy for Engineering and Technology

3.4 Types of helical gear

Double helical gears are used frequently for power

transmission in gas turbines, generators, prime
movers, pumps, fans, and compressors in maritime
ships and construction machinery due to their benefits

A herringbone gear is a particular kind of double helical

gear. The herringbone gear has two sets of gear teeth—
one set on the right hand and one on the left hand—on
a single gear. When there are two sets of gear teeth, one
set's thrust cancels the other. When visible of the top,
each of this gear's spiral grooves resemble the letter V
and form a herringbone pattern

pinion transforms the circular pinion's rotating motion

into linear motion at the rack. A rack is just a straight
bar with gear teeth, Helical racks and pinions are
affordable for linear motion with movement lengths
greater than 2 meters. They transform rotational
motion into linear motion when combined. The rack is
driven in a line when the pinion is rotated.

22
Modern Academy for Engineering and Technology

Screw gears are made for moderate speeds and

torques, such as those used in machine tool drives

Helical worm gears are cylindrical objects with an

external spiral thread that meshes with another
gear to turn it. A worm or a screw collides with a
gear in this particular gear system. Various
industries use worm gears to increase torque and
when significant gear reductions are required.

23
Modern Academy for Engineering and Technology

4.0 Worm gear

A worm gear is a staggered shaft gear that creates motion between shafts using threads that are
cut into a cylindrical bar to provide speed reduction. The combination of a worm wheel and
worm are the components of a worm gear. Speed reduction is determined by the number of
worm threads and the number of teeth on the worm wheel

4.1 Worm gear design

24
Modern Academy for Engineering and Technology

4.2 Worm gear is made:

1. Design the Worm Gear: Use a 3D modeling software to design the worm gear, ensuring

that the gear dimensions are appropriate for your specific application. Ensure that the

gear has a hole in the center to allow for mounting onto a shaft.

2. Export the Design: Export the 3D model file in a format that is compatible with your 3D

printer. Common file formats used for 3D printing include STL, OBJ, and 3MF

3. Prepare the Printer: Set up the 3D printer according to the manufacturer's instructions.

Make sure the printer is calibrated properly, and that the printer bed is level.

4. Load the Material: Load the material that you want to use for printing the gear.

Common materials used for 3D printing gears include ABS, PLA, Nylon, and TPU.

5. Print the Gear: Upload the 3D model file to the 3D printer software, and select the

appropriate print settings such as layer height, print speed, and infill density. Start the print job and wait
for the printer to finish.

6. Post-Processing: After the print is finished, remove the worm gear from the printer bed and clean up
any excess material or support structures that may be attached. Depending on the material used, you
may need to do additional post-processing steps such as sanding or painting.

Note
It's important to note that 3D printing may not be suitable for all applications of worm gears, as
the printed gears may not have the same strength and durability as gears that are machined or
cast. Therefore, it's important to consider the specific requirements of your application before
deciding to use 3D printing for making a worm gear.

25
Modern Academy for Engineering and Technology

5.0 Conclusion

Gear manufacturing is a crucial component of modern industry, with applications in everything

from automobiles to industrial machinery. This report has explored the various methods of gear
manufacturing, including casting, forging, and machining, as well as the materials and design
considerations involved. It has also discussed the importance of quality control and testing to
ensure that gears meet the necessary standards for safety and performance.

Overall, the report highlights the vital role that gear manufacturing plays in enabling many
modern technologies, and underscores the importance of continued research and development
in this field. With advances in materials, design, and manufacturing processes, gear
manufacturers can continue to drive progress in industries ranging from transportation to
energy production

26
Modern Academy for Engineering and Technology

6.0 References

1. [Link]

2. [Link]

3. [Link]

4. [Link]

27