Experiment No.

Advanced Manufacturing Processes

Experiment No. 2
Introduction : Gears are one of the most commonly used elements in almost all simple or complex mechanisms. It is therefore essential for all mechanical engineering students to know all about gears, their manufacturing, machines and processes used for gear making. It is expected that students, learn the principles, processes, procedures and practices used for gear manufacturing, particularly gear hobbing, gear shaping and gear finishing processes. However with the available setup in the Workshop following experiment should be carried out. The student should prepare the report of the gear manufacturing methods employed in Industries in the Industrial Visits.

1.0

Title : Spur gear cutting using Indexing on Milling Machine.

2.0

Prior Concept : 1. 2. 3. Milling processes. Cutter mounting in correct position. Knowledge of spur gear.

3.0

New Concept : Indexing process.

4.0

Learning Objectives : Intellectual : Selection of form cuter for cutting gear. To understand different Indexing processes. Motor skill : Setting cutter and job in correct position. Use of indexing head.

5.0

Design of Experiment : Work Piece : - Low carbon steel blank 67.5mm x 25mm thick with bore 25.00mm Equipment / Tools : 1) Dividing head. 2) Gear cutter for cutting 2.5 modules. Work piece : -

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Advanced Manufacturing Processes

Experiment No. 2

6.0

Stepwise Procedure : Sr. No. 01 02 03 04 05 06 07 Operation Mount and align the dividing head and tailstock on machine table. Mount the gear-milling cutter on the arbor and test for concentricity. Hold the work piece on the mandrel and adjust the mandrel between centres. Adjust the work piece to the centre of cutter. Set the revolutions, and feed for milling. In the beginning the cutter should shave slightly on the work piece. Withdraw the work piece out of range of the cutter and lift the milling table by the height of the tooth depth. Milling of first tooth space. Withdraw the work piece from the cut and turn the indexing handle by the tooth pitch & mill next tooth space. Repeat the procedure for next tooth. Tools / Equipment Dividing head, tail stock, dial . indicator Gear cutter. Try square, slip gauges.

08 09

10

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Gear Milling Setup For The Forming Method : -

1. 2. 3. 4. 5. 6.

Gear Blank Mandrel Tail Stock Dividing Head Table Cutter

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Experiment No. 2

Advanced Manufacturing Processes

a) Dividing Head Setup

b)

a) For differential indexing. b) For helical milling.

8.0

Measuring and Testing of Gears : Vernier Gear Tooth Caliper Vernier Tooth Caliper a) Vertical vernier slide b) Horizontal vernier slide

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

Advanced Manufacturing Processes

Experiment No. 2

Vernier Gear Tooth Caliper : Used for measuring thickness of tooth set the vertical slide and measure Hk. Refer table and check it for the gear. You can find the chordal thickness from the table given below.

Table: -

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Experiment No. 2

Advanced Manufacturing Processes

Measuring of pitch can be done by gear tooth micrometer.

9.0

Questions: - (Attempt 3-5 questions as directed by teacher)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. What is indexing? List the parts of dividing head & state function of each. For what purpose the index plate is provided? State the precautions you will set while setting the cutter on arbor. If m= , T= What is the PCD? What is the size of blank? (teacher can suggest different values of m and T) In spur gear which parameters you will inspect? Explain the difference between simple indexing and compound indexing. Find out the crank movement for cutting 60 divisions on a blank. What are the methods of finishing the cut gears? List the processes applied for gear teeth finishing.

Note: - The staff member should give a briefing to students regarding gear cutting machines, gear cutting methods / operations tooling and setup.

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

Advanced Manufacturing Processes

Experiment No. 2

(Space for answer)

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

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Experiment No. 2

Advanced Manufacturing Processes

(Space for answer)

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