The document discusses the manufacturing process for gears made of AISI 4140 steel. Round bars of the material are cut into shorter cylinders called gear blanks. Teeth are then formed on the blanks through a milling process. Milling involves securing individual gear blanks to a shaft inside a milling machine. A cutter rotates to cut teeth into the blank as it moves laterally. Milling is preferred over other methods as the rotating cutter allows for faster cutting speeds and longer tool life. After milling, further machining like grinding may be done to achieve a fine tolerance on the teeth.
The document discusses the manufacturing process for gears made of AISI 4140 steel. Round bars of the material are cut into shorter cylinders called gear blanks. Teeth are then formed on the blanks through a milling process. Milling involves securing individual gear blanks to a shaft inside a milling machine. A cutter rotates to cut teeth into the blank as it moves laterally. Milling is preferred over other methods as the rotating cutter allows for faster cutting speeds and longer tool life. After milling, further machining like grinding may be done to achieve a fine tolerance on the teeth.
Original Description:
Description of materials used in gear design and the manufacturing methods
The document discusses the manufacturing process for gears made of AISI 4140 steel. Round bars of the material are cut into shorter cylinders called gear blanks. Teeth are then formed on the blanks through a milling process. Milling involves securing individual gear blanks to a shaft inside a milling machine. A cutter rotates to cut teeth into the blank as it moves laterally. Milling is preferred over other methods as the rotating cutter allows for faster cutting speeds and longer tool life. After milling, further machining like grinding may be done to achieve a fine tolerance on the teeth.
The document discusses the manufacturing process for gears made of AISI 4140 steel. Round bars of the material are cut into shorter cylinders called gear blanks. Teeth are then formed on the blanks through a milling process. Milling involves securing individual gear blanks to a shaft inside a milling machine. A cutter rotates to cut teeth into the blank as it moves laterally. Milling is preferred over other methods as the rotating cutter allows for faster cutting speeds and longer tool life. After milling, further machining like grinding may be done to achieve a fine tolerance on the teeth.
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Gear Material ----AISI 4140 through hardened grade 1
A manufacturing and assembly plan (with pictures and/or figures) that details how the product will be manufactured and that estimates the per unit production cost. 8
Figure 1: AISI 4140 Round Bars
All gears start as a long solid round bar of the required material (AISI 4140 in this case) as shown in the image above. The long round bars are then cut into shorter cylinders. These cylindrical blocks are known as gear blanks. Gear blanks are made simply by cutting the round bar into pieces with lengths that are equal to the required thickness of the gear. From here, several processes can be used to form the gear teeth.
Teeth forming
There are many ways of forming the teeth of gears such as sand casting, permanent mould casting, die casting and centrifugal casting and many other ways. These gears will be manufactured by milling. The gearbox uses a total of four gears but two of them have the same dimensions therefore only three cutters will be used for the entire tooth manufacturing process.
Figure 2: Sample Cutter
This manufacturing method (milling) will be achieved through the use of the cutter above. Depending on the quantity of gears that need to be produced one of two instruments will be used , the lathe or a CNC milling machine. CNC is expensive but very efficient and therefore only if a vast number of gears has to be produced will CNC milling be used. The manufacturing process works as follows. A hole that has the diameter of the shaft is drilled through the gear blank and the gear blank is attached to a shaft that goes into the milling machine. The hole tolerances should be observed to maintain the function of the gearbox. Once the gear blank is secured, a cutter is also installed on the top part of the milling machine as shown in the picture below. The machine is then started and as the cutter rotates the gear blank is moved laterally so that the teeth can be cut into it. After each tooth is cut, the gear blank has to be rotated (it rotates automatically on the CNC) and the cutting process occurs all over again.
Figure 3: Milling in Operation
For this project, milling is best because
The inserts rotate as they cut
Faster cutting speeds allow faster feed rates Rotating inserts last longer Intermittent cuts do not create problems There is less wear of machinery
After the milling process the teeth may need to be further machined and grinding shall be used to produce a fine tolerance.
