Introduction to Gear Manufacturing Technology: functional principles, technological fundamentals, materials, heat treatments, quality criteria, accuracy requirements, and manufacturing costs. Structure of a manufacturing process for a disc-type gear. Structure of a manufacturing process for a splined shaft.
Manufacturing of cylindrical gears by the form cutting method. Recommendations regarding cutting parameters and machining conditions. Available CNC equipment.
Manufacturing of cylindrical gears by the generating method using single-start or multi-start hobs. Selection of milling direction. Estimation of machining time and process optimisation. Determination of maximum chip thickness. Available CNC machines.
Gear shaping using the generating method with a gear shaper cutter. Types of cutting tools. Tool materials and coatings. Operating parameters. Prevention of interference. Available CNC machines. Gear manufacturing by broaching. Tool construction. Operating parameters. Determination of machining time. Available machines.
Gear finishing by shaving and grinding using biconical grinding wheels (NILES), dish-shaped grinding wheels (MAAG), and grinding worms (REISHAUER). Available machines. Analysis of the requirements of relevant industry standards.
Worm gear manufacturing technology. Machining of profiled worms by turning. Milling and grinding of worms. Machining of worm wheels using radial and tangential feed.
Bevel gear machining technology. Specific technological issues, including the selection of technological datums and the machining of non-toothed surfaces. Cutting technology for straight-tooth and inclined-tooth bevel gears. Finishing of bevel gear tooth flanks.
Manufacturing technology for circular-arc tooth gears. Manufacturing technology for spiroid and helical gears.
Resharpening of gear-cutting tools. Accuracy of manufactured gears depending on the machining process employed. Analysis of the Klingelnberg diagram. Emerging developments involving artificial intelligence.
II. Laboratory Works
Presentation of occupational health and safety regulations and laboratory activities. Review of the geometrical elements of gears and useful formulas for defining spur and helical gears.
Experimental analysis of gear cutting using the form cutting method with a profiled disc cutter for cylindrical spur gears.
Adjustment of the technological system and determination of machining accuracy for cylindrical helical gears manufactured using the form cutting method.
Manufacturing of cylindrical spur gears using the generating method (gear hobbing).
Adjustment of the technological system and determination of machining accuracy for cylindrical helical gears using hob cutters.
Experimental study of the generating process for machining splined shafts.
Design and manufacture of a spur gear using rapid prototyping methods.
ECTS credits
4
Teaching Language
English
Exam Language
English
Support Materials Language
English
Basic Learning Outcomes
Course categorized
Managing Entity (faculty)
Faculty of Industrial Engineering, Robotics and Production Management (UTCN)
