SUBMITTED BY:

1. Kishan Panchal (146330319073)

2. Ronak Panchal (146330319078)
3. Yash Panchal (146330319081)

Manufacturing Engineering-III

Mechanical Engineering Department

L. J. POLYTECHNIC, AHMEDABAD
 Gear Milling

• Manufacture of gear by milling process is q

uite familiar and is used for gear cutting.
• In this process machining of gear blank is do
ne using a form cutter.
• The production of spur, helical, bevel, worm
, worm wheel type gears can be done.
• Mainly two types of cutters are used in gear
milling:-

1. End-mill cutter, which is directly fixed in t

he spindle.

2. Disc type form cutting is fixed on the arbor

of milling machine.
1.End mill-cutter 2.Disc type form cutter
• End milling cutter is mainly used to cut large pitch
pinions while the disc cutter is used to cut spur ge
ar where large amount of material is removed.
• For Gear milling, form cutter is fitted on the horiz
ontal or vertical milling machine and gear blank is
rotated by accurate angle with the help of universa
l indexing mechanism.
• The blank is rotated while cutting spur gear, while
the work table is moved forward and backward.
• After cutting the nearby spaces, one gear tooth be
comes ready.
• Universal milling machine is used for cutting helic
al gear, in which table is arranged at helix angle an
d gear blank is rotated by gear train with the help o
f a universal dividing head as shown in the below fi
gure.

Indexing Mechanism
 Advantages
1. All type of gear can be manufactured
2. Roughing and finishing both process can be done.
3. Benefited for small work pieces.
4. Tooth profile which cannot be generate by other for
ming process, gear milling provide high accuracy wi
th complicated profiles.
5. Its is a flexible process.
  Limitations
1. Accuracy can not be specific, as gears are cut by ind
exing.
2. more numbers of gear cutters are required.
3. Gear tooth shape completely depend on cutter, hence
there are chances of variation in shape.
4. gear milling is not advisable for mass production.
5. The process is limited only for coarse pitch gears.
 Gear Broaching
• Gear broaching is a high production & high accuracy
process.
• It is mainly used to manufacture internal gears.
• Helical and spur gear production can be done by broa
ching.

1. Spur gear 2. Helical gear

• Various steps of the broaching process are as under:

1. The tooth space is cut by one complete stroke of th

e broach, after indexing a gear blank large ring gea
r can be produced by the this method in while verti
cal broaching machine is used.
2. Simultaneous broaching is to be done on more tha
n one blank by arranging them on the machine.
3. Broaching of more than one tooth at a time is also
possible.
4. Some time all the teeth are cut in one stroke of the
broach and accuracy of the circular pitch is mainta
ined as indexing is not required in this case.
  Advantages

1. Gear can be finished in single cut.

2. Small gears can be produced easily.
3. it is more suitable & economical for internal gear
cutting.
4. Production rate and accuracy is more in comparis
on to gear milling.
  Limitations

1. Broach is a special type of tool hence separate too

l is required for each variety of gear.
2. Broaching is not useful for bevel & worm gear.
3. External broaching is not useful mainly due to its
difficult nature and very hard to tackle it.