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Forging new generations of engineers

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  1. Forging new generations of engineers

  2. Gear Cutting

  3. MakingGears • Gear cutting equipment • Preparing a gear blank • Gear involute cutters • Cutting a spur gear • Identify current gear uses • Apply gear knowledge to real situations

  4. Diametral Pitch Diametral Pitch is the actual size of the gear tooth.The lower the number the larger the tooth.The chart at left shows 3 dp. as larger tooth and 20 dp as the smallest tooth. 3 dp 20 dp

  5. Gear Tooth Parts

  6. Gear Cutting Equipment • Metal Lathe • Horizontal Mill • Horizontal Cutoff Saw • Indexing Head • Drill Bit • Gear Involute Cutter • Gear Blank & Mandrel

  7. Horizontal Mill Saw Cutoff Band Saw Gear Cutting Equipment

  8. Gear Cutting Equipment Metal Lathe Drill Gear ToothGage Gear Blank Gear Cutter Mandrel

  9. Horizontal Cutoff Saw Cutting Gear Blank

  10. Metal Lathe Used To Face Sides Of Gear Blank And Drill A 1” Hole

  11. Rough Gear Blank Mounted On A Mandrel

  12. Mandrel And Gear Blank Assembly Mounted On The Lathe Turned To Finished Gear Diameter And Thickness

  13. Indexing Head Used To Exactly Position Gear Blank To Cut Each Tooth

  14. Math Gear Calculations • 16 Diametral Pitch X 2 Inch Diameter Gear Blank Equals Number Of Teeth • N = D.P. X D.G. N = 16 X 2 N = 32 Teeth • 40 Turns Of The Dividing Head Hand Crank Equals 1 Revolution Of The Gear Blank • Turns = 40/32 = 10/8 = 5/4 = 1 And 1/4 Turns

  15. Math Gear Calculations • Using a 20 hole plate 1/4 turn = 20/4 = 5 spaces or 6 holes in plate. This moves our gear blank 1 and 1/4 turns. • Outside diameter of gear = 32th + 2/16 =2.125 • Cutting depth for tooth = 2.250 a constant divided by d.P. • Depth = 2.250/16 = .140 thousands for depth of cut.

  16. 20 Hole Indexing Plate Mounted On Indexing Head

  17. Horizontal Mill Set Up With Indexing Head, Mandrel & Gear Blank

  18. Horizontal Mill Set Up To Cut Gear

  19. Gear Blank Aligned With Gear Involute Cutter

  20. Gear Involute Cutter Cutting Gear

  21. Checking Finished Gear With Involute Gage

  22. Measuring Finished Gear