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Valery Marinov, Manufacturing Technology Gear Manufacturing 123
6.6 GEAR MANUFACTURING
Introduction
Because of their capability for transmitting motion and power, gears are among the most important
of all machine elements. Special attention is paid to gear manufacturing because of the specific require-
ments to the gears. The gear tooth flanks have a complex and precise shape with high requirements
to the surface finish.
Gears can be manufactured by most of manufacturing processes discussed so far (casting, forging,
extrusion, powder metallurgy, blanking). But as a rule, machining is applied to achieve the final
dimensions, shape and surface finish in the gear. The initial operations that produce a semifinishing part
ready for gear machining as referred to as blanking operations; the starting product in gear machining
is called a gear blank .
Two principal methods of gear manufacturing include
gear forming, and
gear generation.
Each method includes a number of machining processes, the major of them included in this section.
Gear forming
In gear form cutting, the cutting edge of the cutting tool has a shape identical with the shape of the
space between the gear teeth.
The principle of gear
forming.
Two machining operations, milling and broaching can be employed to form cut gear teeth.
Form milling
In form milling , the cutter called a form cutter travels axially along the length of the gear tooth at
the appropriate depth to produce the gear tooth. After each tooth is cut, the cutter is withdrawn, the
gear blank is rotated (indexed), and the cutter proceeds to cut another tooth. The process continues
until all teeth are cut.
Setup of form milling. Form milling of a helical
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