Six Month Industrial Training
SIX MONTHS INDUSTRIAL
TRAINING REPORT
Held at
NAPCO BEVEL GEAR OF INDIA LIMITED
(33 Miles Stone,MathuraRoad,Faridabad,Haryana)
Submitted in partial fulfilments of the requirement for the award of
the degree of
BACHELOR OF TECHNOLOGY
(“Mechanical Engineering”)
In
“ U.I.E.T.’’
SUBMITTED BY:
PAWAN
Roll no :15742
University Institute of Engineering & Technology
[Link], Rohtak-124001
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Table of Contents
Topic Page No.
1. INTRODUCTIONTO COMPANY
2. MACHINING
2.1. ROUGHING
2.1.1. FORM MILLING
2.1.2. RACK GENERATION
2.1.3. GEAR SHAPING
2.1.4. HOBBING
[Link]
2.2.1. SHAVING
2.2.2. GRINDING
2.2.3. BURNISHING
2.2.4. LAPPING & HOWNING
3. QUALITY OF GEARS
4. MANUFACTURING OF GEARS
5. FORMATION OF TYPES OF BEVEL GEARS
5.1. STRAIGHT BEVEL GEARS
5.2. ZEROL BEVEL GEARS
5.3. SPIRAL BEVEL GEARS
6. MATERIAL SELECTION
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1. INTRODUCTION TO COMPANY:
A gear is a mechanical device often used in transmission systems that allows
rotational force to be transferred to another gear or device. The gear teeth, or cogs,
allow force to be fully transmitted without slippage and depending on their
configuration, can transmit forces at different speeds, torques, and even in a
different direction. Throughout the mechanical industry, many types of gears exist
with each type of gear possessing specificbenefits for its intended applications.
Bevel gears are widely used because of their suitability towards transferring
power between nonparallel shafts at almost any angle or speed. Spiral bevel gears
have curved and sloped gear teeth in relation to the surface of the pitch cone. As a
result, an oblique surface is formed during gear mesh which allows contact to
begin at one end of the tooth (toe) and smoothly progress to the other end of the
tooth (heel), as shown below in Figure 1. Spiral bevel gears, in comparison to
straight or zerol bevel gears, have additional overlapping tooth action which
creates a smoother gear mesh. This smooth transmission of power along the gear
teeth helps to reduce noise and vibration that increases exponentially at higher
speeds. Therefore, the ability of a spiral bevel gear to change the direction of the
mechanical load, coupled with their ability to aid in noise and vibration reduction,
make them a prime candidate for use in the helicopter industry.
Fig 1: Napco Bevel Gear of India Lmt. Logo
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2. MACHINING
The bulk of power transmitting metal gears of machinery are produced by
machining process from cast, forged, or hot rolled blanks. Refer fig 2 for
classification of machining processes. Roughing processes include milling the
tooth shape with formed cutters or generating the shape with a rack cutter, a
shaping cutter or a hob cutter which are show
Fig 2: Gear Cutting process
Despite its name, the roughing processes actually produce a smooth and accurate
gear tooth. Only for high precision and quiet running, the secondary finishing
operation is justified at added cost.
2.1. Roughing processes:
Roughing process consists of forming, generation, shaping and hobbing processes.
By this method gears are made to an accuracy which is more than adequate for the
slow speed operations. These processes are dealt here.
2.1.1 Form milling:
Forming is sub-divided into milling by disc cutters and milling by end mill cutter
which are
having the shape of tooth space.
2.1.1a Form milling by disc cutter:
The disc cutter shape conforms to the gear tooth space. Each gear needs a separate
cutter. However, with 8 to 10 standard cutters, gears from 12 to 120 teeth can be
cut with fair accuracy. Tooth is cut one by one by plunging the rotating cutter into
the blank as shown in fig 3.
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Fig3: Form milling by disc cutter
2.1.1b Form milling by end mill cutter:
The end mill cutter shape conforms to tooth spacing. Each tooth is cut at a time
and then indexed for next tooth space for cutting. A set of 10 cutters will do for 12
to 120 teeth gears. It is suited for a small volume production of low precision
gears. The form milling by end mill cutter. To reduce costs, the same cutter is
often used for the multiple-sized gears resulting in profile errors for all but one
number of teeth. Form milling method is the least accurate of all the roughing
methods.
2.1.2 Rack generation:
In rack cutter the tooth shape is trapezoid and can be made easily. The hardened
and sharpened rack is reciprocated along the axis of the gear blank and fed into it
while gear blank is being rotated so as to generate the involute tooth on the gear
blank as shown fig 4.
Fig 4: Generation of involute tooth on gear blank
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The rack and gear blank must be periodically repositioned to complete the
circumference. This introduces errors in the tooth geometry making this method
less accurate than shaping and hobbing.
The process is limited to small gears since the length of the rack has to be equal to
circumference of the gear at pitch diameter. The generation of spur gear by
planing.
2.1.3 Gear shaping:
Gear shaping used a cutting tool in the shape of a gear which is reciprocated
axially across the gear blank to cut the teeth while the blank rotates around the
shaper tool. It is a true shape-generation process in which the gear-shaped tool
cuts itself into mesh with the gear blank as shown in fig 5. The accuracy is good,
but any errors in one tooth of the shaper cutter will be directly transferred to the
gear. Internal gears can be cut with this method as well.
Fig5 Gear shaping
2.1.4 Hobbing:
Hob teeth are shaped to match the tooth space and are interrupted with grooves to
provide cutting surfaces. It rotates about an axis normal to that of the gear blank,
cutting into the rotating blank to generate the teeth.
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Fig 6: Hobbing
It is the most accurate of the roughing processes since no repositioning of tool or
blank is required and each tooth is cut by multiple hob-teeth, averaging out any
tool errors. Excellent surface finish is achieved by this method and it is widely
used for production of gears.
2.2 Finishing Processes:
When high precision is required secondary operation can be performed to gears
made by any of the above roughing methods. Finishing operations typically
removes little or no material but improves dimensional accuracy, surface finish, and
or hardness. The various finishing processes are
2.2.1 Shaving:
Shaving is similar to gear shaping, but uses accurate shaving tools to remove
small amounts of material from a roughed gear to correct profile errors and
improve surface finish. Shaving operation is shown in fig 7.
Fig 7: External gear being shaved
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2.2.2. Grinding:
In grinding, a contoured grinding wheel is run over machined surface of the gear
teeth using computer control. With a small amount of metal removal high surface
finish is obtained. Fig8 shows grinding operations and dressing of the wheel.
Fig 8: Grinding machine
2.2.3 Burnishing:
In burnishing, a specially hardened gear is run over rough machined gear.
The high forces at the tooth interface cause plastic yielding of the gear
tooth surface which improves finish and work hardens the surface creating
beneficial compressive residual stresses.
2.2.4 Lapping and Honing:
Lapping and honing both employ an abrasive-impregnated gear or gear-shaped
tool that is run against the gear to abrade the surface. In both cases, the abrasive
tool drives the gear in what amounts to an accelerated and controlled run-in to
improve surface finish and the accuracy. Fig9 shows lapping operation for bevel
gears.
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Fig 9: Special bevel gears being lapped
3. QUALITY OF THE GEAR
The quality of gear gives its accuracy, dimensional and profile which dictates the
suitability of gears for different operations.
Gear quality, their limiting speeds and dynamic load factors
Table Alloiable velocities and applications of gears of various accuracy grades
---------------------
Manufacture of gears needs several processing operations in sequential stages
depending upon the material and type of the gears and quality desired. Those
stages generally are :⎯ Preforming the blank without or with teeth ⎯ Annealing of
the blank, if required, as in case of forged or cast steels ⎯ Preparation of the gear
blank to the required dimensions by machining ⎯ Producing teeth or finishing the
preformed teeth by machining ⎯ Full or surface hardening of the machined gear
(teeth), if required ⎯ Finishing teeth, if required, by shaving, grinding etc. ⎯
Inspection of the finished gears.
Fig.10. Gear quality measurement
[Link] OF GEARS
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Spiral bevel gears are currently used in all helicopter power transmission systems.
This type of gear is required to turn the corner from a horizontal engine to the
vertical rotor shaft. These gears carry large loads and operate at high rotational
speeds. Recent research has focused on understanding many aspects of spiral
bevel gear operation, including gear geometry, gear dynamics, lubrication, stress
analysis and measurement, misalignment and coordinate measurements, as well as
other areas.
[Link] OF TYPES OF BEVEL GEARS:
Fig 11: Spiral Bevel GearFig 12: Straight Bevel Gear
6. MATERIAL SELECTION
The specifc application of a gear determines the necessary material properties and
additional treatments that may be required. Additional treatments typically
considered are through hardening and surface hardening, which includes but is not
limited to carburization, nitriding, induction hardening, and fame hardening.
Through hardened steels are used when medium wear resistance and load carrying
capacity are desired whereas carburized and hardened gears are used when high
wear resistance and high load carrying capacity are required [5]. Specifcally, the
desired loading and desired design life are integral in selecting the proper material
and any additional treatment that may be required. Many years of gear industry
experience has led the design community to rely on carburized, case-hardened
steel for bevel gears. Testing has been performed on these types of materials and
allowable stresses have been derived as a result of these widely recognized test
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results. Therefore, spiral bevel gear materials are limited to only those which are
easily carburized and case-hardened.
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