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Gears (a.k.a. cogwheels), are basically rotating machines (in the shape of
wheels or cylinders) that have cut teeth or cogs and mesh with another such
set up to transmit torque or rotary and reciprocating motion from one part of
a machine to another. Geared devices can change the speed, torque and
direction of a power source. Two or more gears, transmitting motion from one
shaft to another, constitute a gear train or a transmission. Gears almost always
produce a change in torque, creating a mechanical advantage, through their
gear ratio, and thus may be considered as a simple machine. When two gears
mesh, if one gear is bigger than the other, a mechanical advantage is
produced, with the rotational speeds, and the torques, of the two gears
differing in proportion to their diameters. The first ever use of gears dates back
to 4th century BCE in China.
TYPES OF GEARS:
EXTERNAL AND INTERNAL GEARS : The external gears have their teeth
formed on the outer surface of a cylinder or cone. Conversely,
an internal gear is one with the teeth formed on the inner surface of a
cylinder or cone.
SPUR GEAR: Also called as straight cut gears, they are the simplest type
of gears and consist of a cylinder or disk with teeth projecting radially.
Though the teeth are not straight-sided, the edge of each tooth is
straight and is aligned parallel to the axis of rotation. They need to be
fitted to parallel shafts for their proper meshing.
HELICAL GEAR: the leading edges of the teeth are not parallel to the axis
of rotation, but are set at an angle, which forms a helix like segment.
Helical gears can be arranged in both parallel and crossed orientations.
DOUBLE HELICAL GEAR: A double helical gear can be thought of as two
mirrored helical gears joined together. This arrangement cancels out the
net axial thrust , since each half of the gear thrusts in the opposite
direction resulting in a net axial force of zero. A similar type of gear is
the Herringbone gear.
BEVEL GEAR: A bevel gear is shaped like a right circular cone with most
of its tip cut off. When two bevel gears mesh, their imaginary vertices
must occupy the same point. Their shaft axes also intersect at this point,
forming an arbitrary non-straight angle between the shafts. The angle
between the shafts can be anything except zero or 180 degrees.
SPIRAL BEVEL GEAR: Spiral bevel gears can be manufactured as Gleason
types (circular arc with non-constant tooth depth), Oerlikon and Curvex
types (circular arc with constant tooth depth), Klingelnberg Cyclo-Palloid
(Epicycloide with constant tooth depth) or Klingelnberg Palloid.
HYPOID GEAR: Hypoid gears resemble spiral bevel gears except the shaft
axes do not intersect. The pitch surfaces appear conical but, to
compensate for the offset shaft, are in facthyperboloids of
revolution.Hypoid gears are almost always designed to operate with
shafts at 90 degrees.
CROWN GEAR: Crown gears or contrate gears are a particular form of
bevel gear whose teeth project at right angles to the plane of the wheel;
in their orientation the teeth resemble the points on a crown. A crown
gear can only mesh accurately with another bevel gear, although crown
gears are sometimes seen meshing with spur gears.
WORM GEAR: Worms resemble screws. A worm is meshed with a worm
wheel, which looks similar to a spur gear. Worm-and-gear sets are a
simple and compact way to achieve a high torque, low speed gear ratio.
RACK AND PINION: A rack is a toothed bar or rod that can be thought of
as a sector gear with an infinitely large radius of curvature. Torque can
be converted to linear force by meshing a rack with a pinion: the pinion
turns; the rack moves in a straight line.
Various other types of gears include magnetic gear, cage gear, epicyclic
gear etc.
BASIC TERMINOLOGIES
PITCH CIRCLE DIAMETER-It is the diameter o the pitch circle. The size of
the gear is usually specified by the pitch circle diameter. It is also called
the pitch diameter.
PITCH SURFACE-It is the surface of the rolling discs which the meshing
gears have replaced at the pitch circle.
ADDENDUM CIRCLE-It is the circle drawn through the top of the teeth
and is concentric with the pitch circle.
Forging:
Forging, process of shaping iron and other malleable metals by hammering or
pressing them after making them plastic by application of heat. Forging
techniques are useful in the working of metal because the metal can be given
the desired form, and the process improves the structure of the metal,
particularly by refining the grain size of the metal. Forged metal is stronger and
more ductile than cast metal and exhibits greater resistance to fatigue and
impact.
Rolling:
Cylindrical blanks are prepared by roll forming. In this type three rollers are
arranged and material is place in between them. So that a blank of required
surface finish is obtained.
Extrusion:
Extrusion is a process of forcing substances, especially metals or
thermoplastics, through a die to produce various shapes of uniform cross
section widely used in industry and constructions. Hot extrusion being more
common than cold extrusion. The manufacturing of cylindrical hollow blanks is
done by such extrusion process.
Milling process 1
4.PLANING OF GEAR :-
This process is also called as rack generation. This process is used for
shaping of spur and helical gear teeth with the help of a rack type cutter.
In this process the gear blank is mounted on a horizontal aims and
rotated impertinently. At the same time the gear blank is kept in mesh
with a reciprocating rack type cutter. The teeth cutter gradually removes
material to cut the teeth and to make the required profile. The whole
operation includes some important operations. These are feeding cutter
into the blank, rolling the blank intermittently and keeping cutter in
mesh with the rolling gear blank. After each mesh the gear blank is
rolled by an amount equal to one pitch of gear tooth. After each cutting,
the rack is withdrawn and re-meshed after the rotation of gear blank.
7. GEAR HOBBING :-
In addition to the gear shaping process another process used for gear
generation is gear hobbing. In this process, the gear blank is rolled with a
rotating cutter called hob. Gear hobbing is done by using a multipoint
cutting tool called gear hob. It looks like a worm gear having a number of
straight flutes all around its periphery parallel to its axis. These flutes are
so shaped by giving proper angles to them so that these work as cutting
edges. In gear hobbing operation, the hob is rotated at a suitable rpm
and simultaneously fed to the gear blank. The gear blank is also kept as
revolving. Rpm of both, gear blank and gear hob are so synchronized
that for each revolution of gear bob the gear blank rotates by a distance
equal to one pitch distance of the gear to be cut. Motion of both gear
blank and hob are maintained continuously and steady.
Gear hobbing is also used for making a wide variety of gears like spur
gear, helical, hearing-bone, splines and gear sprockets, etc.
The hobbing processes can be classified basing upon the feed of the gear into
the machine, viz.
In CNC machine the program is stored in the memory of the computer. The
programmer can easily write the codes, and edit the programs as per the
requirements. These programs can be used for different parts, and they don’t
have to be repeated again and again.
Each axis has its own independent driving system and position measuring
system.
CNC machine requires (a) high quality guide ways for precise positioning of the
individual axes by traversing without stick slip, and (b) thermal and mechanical
stability for better and consistent accuracy.
CARBURIZATION
Carburization of steel involves a heat treatment o the metallic surface using a
source of carbon. Early carburization used a direct application of a charcoal
packed into the metal (initially referred to as case hardening), but modern
techniques apply carbon bearing gases or plasma (such as carbon dioxide or
methane). The process depends primarily upon ambient gas composition and
furnace temperature, which must be carefully controlled, as the heat may also
impact the microstructure of the rest of the material. The application where
great control of over gas composition is desired carburization may take place in
a very low pressure in a vacuum chamber.
The carbon content of case hardening steel is low, usually about 0.15 to 0.20
%. Case hardening steel also contains Ni, Cr, Mo, Mn, etc. It is suitable for
carburizing and quenching.
For such hardening the process followed is as follows
CARBURIZINGQUENCHINGCLEANING
TEMPERINGSHOT BLASTINSPECTION.
Case hardened steel is usually formed by diffusion of carbon (carburizing) into
the outer layer of the steel at high temperature. And putting carbon into the
surface of steel makes it high-carbon steel like S45C, which can be hardened by
heat treatment.
Surface hardness is about 55~60 HRC.
Depth of surface hardening is about 1.0 mm.
Carburizing and quenching produces a hard, wear resistant surface over a
strong tough core. Some special purpose steel gears are case hardened by
either carbo-nitriding or nitriding. Other special purpose gears, such as those
used in chemical or food processing equipment, are made of stainless steel or
nickel based alloy or carburized because of their corrosion resistance, their
ability to satisfy sanitary standards or both.
HARDENING
Hardening consists of heating the steel to proper austenitising temperature,
soaking of this temperature to get fine–grained and homogenous austenite,
and then cooling the steel at a rate faster than its critical cooling rate. Such
cooling is called quenching. Normally, carbon steels are quenched in water,
alloy steels in oil (as critical cooling rate of alloy steels is much less), etc.
OBJECTIVE OF HARDENING
Hardening is done to all tools, heavy – duty carbon steel machine parts and
almost all machine parts made of alloy steels.
1. Main aim of hardening tools is to induce high hardness. The cutting
property of the tool is directly proportional to the hardness of the steel.
2. Many machine parts and all tools are also hardened to achieve high
wear resistance. Higher is the hardness, higher is the wear and abrasion
resistance. For example, spindles, gears, shafts, cams, etc.
3. Develop high yield strength with good toughness and ductility, so that
higher working stresses are allowed.
TEMPERING
DEFINITION
Heating the steel to a tempering up to lower critical, soaking followed by slow
cooling. Temperature of tempering is decided by final required hardness and
type of steel.
OBJECTIVE
1. To relieve internal stresses
2. To restore ductility and toughness, however there is loss of strength
3. To stabilize dimension
4. To improve magnetic properties, as austenite is non-magnetic.
DISAVANTAGES
Manufacturing of gear is complex.
Special tools and equipments are needed to manufacture them.
In cases of errors or inaccuracy in manufacturing in manufacturing it
would create vibrations at high speed.
It is suitable for large center distance.
If profile of the job is not perfect, then the involutes profile can’t be
obtained even grinding it leads to profile error. Any error in pitch of the
job causes pitch error in a gear.
Pressure angles are generally given to the job cutting edges. So if is not
perfect, then pressure angle in the gear will change which will make it
unsuitable for the required application
If the contact pattern doesn’t correspond to the tooth profile then it
shows that the job is defective.
If grinding allowance is more than the carbon deposit of the hardened
portion of the gear gets removed and results of in breakdown of gear.