Gear Design and Production - Industrial Engineering

Gear Production - Basic Process

Gear Materials, Properties, and Manufacture

Joseph R. Davis
ASM International, 2005 - Technology & Engineering - 339 pages

All of the critical technical aspects of gear materials technology are addressed in this new reference work. Gear Materials, Properties, and Manufacture is intended for gear metallurgists and materials specialists, manufacturing engineers, lubrication technologists, and analysts concerned with gear failures who seek a better understanding of gear performance and gear life. This volume complements other gear texts that emphasize the design, geometry, and theory of gears. The coverage begins with an overview of the various types of gears used, important gear terminology, applied stresses and strength requirements associated with gears, and lubrication and wear. This is followed by in-depth treatment of metallic (ferrous and nonferrous alloys) and plastic gear materials. Emphasis is on the properties of carburized steels, the material of choice for high-performance power transmission gearing.
https://books.google.co.in/books?id=x17JAPZnDvQC


An Approach for Systematic Process Planning of Gear Transmission Products
Mats Bagge
Licentiate Thesis, 2009
Royal Institute of Technology, KTH Production Engineering
http://www.diva-portal.org/smash/get/diva2:160163/fulltext01.pdf

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Industrial Engineering of Gear Design and Manufacturing:  Operation analysis and Value Analysis which examine each element and feature of manufacturing operations involved and product design are to be done to identify industrial engineering opportunities and carry out redesign of the operation or product.  To do this we need to maintain developments in engineering related to gears on a continuous basis.

Gear Production - News & Developments 

Reducing Production Costs in Cylindrical Gear Hobbing and Shaping
Fritz Klocke and Claus Kobialka
March/April 2000 issue of Gear Technology.
https://www.geartechnology.com/articles/0300/Reducing_Production_Costs_in_Cylindrical_Gear_Hobbing_and_Shaping/


5/21/2008
Gear Manufacturer Cuts Costs By Reclaiming Used Tools
This gear manufacturer needed to reduce high costs resulting from replacing dull drill bits or sending them out for sharpening. With the XT3000 Xpandable tool sharpener from Darex, the shop has done just that. In addition, the device allows the company to custom-sharpen drills for specific jobs.
https://www.mmsonline.com/articles/gear-manufacturer-cuts-costs-by-reclaiming-used-tools

2011

Computer Aided Process Planning for Machining the Gears
Deepak Byotra, Rajesh Kumar Bhushan
June 2011
Advanced Materials Research (Volumes 264-265)
https://www.scientific.net/AMR.264-265.1551

2012

Reducing Gear Manufacturing Costs at Turning
Posted on: 12/04/2012
https://gearmotions.com/reducing-gear-manufacturing-costs-at-turning/

IMTMA 2012
Gear manufacturing is a fairly complex metal cutting process and forms an integral part of many industrial products. Gears finds a wide
variety of application in diverse industries such as Automobile, Machine Tools, Aerospace, General Engg. and so on. With a growing
demand for better productivity and quality of gears, the manufacturers are now increasingly seeking machine tools and technology that
can meet their requirements. The customer expectations are driven by improved performance, cheaper cost, light weight, better
efficiency, minimal noise, and rapid development.
From the traditional gears made by conventional methods of casting and forging to plastic gears, the technology of Gear manufacturing has
evolved over the years. A combination of innovative manufacturing technologies and superior materials have made the Gear
manufacturing process more simple and productive.



In order to highlight the technology trends, Indian Machine Tool Manufacturers' Association (IMTMA) is organizing a two day seminar
'Latest Trends in Gear Manufacturing' on 11 May 2012 at Gurgaon.
FOCUS AREAS
Overview of Gear Manufacturing in Automotive industries
Ø Evolution of Gear manufacturing processes (soft)
Hobbing & Shaping
Ø New development in Hobbing with case studies & examples
Ø Green teeth finishing of gears – Gear shaving process
Ø Gear materials & Heat Treatment terminologies
Ø Evolution of Heat Treatment Processes
Ø Evolution of Gear manufacturing processes (hard) – Gear
grinding
Ø New development in Grinding with case studies & examples
Ø Gear metrology – AGMA and DIN standards; Inspection &
Testing of different types of gears. Definitions of Important
parameters
Ø Advanced Gear measuring solutions
Ø Gear finishing process – Gear Honing, Polishing, Lapping &
other specialised processes – Characteristics & Specific
applications
Ø Automation in Gear Manufacturing technology

This seminar will be addressed by Industry experts from Chrystec Machine Tool Pvt. Ltd., Liebherr Machine Tools India Pvt. Ltd., Felsomat
India Pvt. Ltd., Reishauer AG/Proteck Machinery Pvt. Ltd., Klingelberg/Francis Klein & Co Pvt. Ltd.

Remanufacturing the Pinion: An Application of a New Design Method for Spiral Bevel Gears
Löwe, Harald & Lei, Baozhen & Cheng, Guang & XunweiWang,. (2013).
Advances in Mechanical Engineering. 2014. 10.1155/2014/257581.

A new material, the Böhler MC90 INTERMET

voestalpine AG Letter to Shareholders, 1st–3rd Quarter 2012/13
The Special Steel Division has developed a new material, the Böhler MC90 INTERMET, that is optimally suited for cutting materials that are difficult to process, such as titanium alloys, stainless steel, or nickel alloys. It is an ideal alternative to cemented carbides, which had been previously used. The MC90 INTERMET is manufactured in a powder-metallurgical process and its thermal properties are superior to the traditional high-speed steel grades, resulting in a far longer service life for the tool.
(It will be interesting to know why this material did not pickup so far* (2020)
https://reports.voestalpine.com/1213/qr/3/managementreport/researchanddevelopment.html

Earlier Collection in 2012 - Gear Manufacturing - Industrial Engineering

Integrating Six Sigma and Theory of Constraints in Gear Cutting

Boom machines six sigma improvement
Gear manufacturers sharpen their teeth
Hard Alloy Gear Circular Saw Blades

State of Gear Technology 2011

2014

We Shall Supply You Low Cost Gearbox - Why Pay for More Than You Need?

Posted by Torque Transmission
2014

One of our customers, a door manufacturer, needed a small right angle 30:1 worm gear reducer for a very low torque requirement at a low RPM.

The problem was that they need it to be corrosion resistant, compact, and economical, in line with amount of work it will do.  The world is full of well designed hi capacity worm gear reducers at high prices, but not what the customer wants or needs.

The solution was a reducer designed to meet the low torque requirements at a price the customer wanted to pay.  Injection molded nylon housing, aluminum shafting, rolled worm,  simple gear design, plastic bearing journals – presto a reducer that meets all the requirements and price as well. The customer was able to get the light weight, corrosion proof gear box they needed at a price that fit their customers budgets.

Contact Torque Transmission today so that we can find a low cost gearbox solution that meets your needs and your budget.
https://www.torquetrans.com/blog/low-cost-gearbox

2016

Selecting the Proper Gear Milling Cutter Design for the Machining of High-Quality Parallel Axis, Cylindrical Gears and Splines
By Brent Marsh -April 18, 2016
https://gearsolutions.com/features/selecting-the-proper-gear-milling-cutter-design-for-the-machining-of-high-quality-parallel-axis-cylindrical-gears-and-splines/




Training Programme on

Gear Manufacturing Processes

Gear manufacturing is a fairly complex metal cutting process and forms an integral part of many industrial products. Gears and Gear drives are one of the key components of all kinds of vehicles, machine tools, aircrafts, household appliances as well as a broad variety of industrial equipments. Proper understanding about the various Gear manufacturing processes and controlling parameters is essential in order to meet the growing demands for better productivity and quality of gears.

Indian Machine Tool Manufacturers' Association (IMTMA) organized a 2 day seminar on Gear Manufacturing Processes for the employee workforce of Hero MotoCorp Ltd on 25-26 May 2016 at Hero MotoCorp , Gurgaon Plant.

The programme focused on :

Introduction, Overview of Gear Manufacturing methods
Gear Machining in soft - Hobbing, Shaping, Shaving
Gear Machining in Hard ? Grinding, Lapping

Gear Hobbing ? Review of basics; Process parameters; Work set up and Hob set up methods; Process optimization.
High speed gear Hobbing with case studies

Gear Shaping ? Working Principle; Process parameters; Work set up and Cutter set up methods; Shaping of internal and external gears; Advantages and limitations of gear Shaping; Industry application examples

Gear Shaving ? Working Principle; Advantages and limitation; Industry application examples
Gear Grinding ? Need for Gear Grinding; Advantages and limitation; Industry application examples; Types of grinding machines;
Gear Grinding - Process parameters; Work set up and wheel set up methods; process optimization;

Live demonstration of Gear manufacturing processes

The Program was conducted by Mr. Ved Parkash, an industry expert with over 37 years of domain expertise in automotive industries. He is former Head - Quality & TQM at Ashok leyland and Head - Quality at Hero Honda Motors.

The programme was highly interactive and participants were able to solicit guidance on specific technical issues from the expert faculty.
http://imtmatraining.in/blog/blog2.php/gear-manufacturing-processes-1

2017

 "Upgrading Your Toolbox" appeared in the May 2017 issue of Gear Technology.

Summary
Manufacturers focus on tool design, materials, coating, machine tool options and cutting parameters.
https://www.geartechnology.com/articles/0517/Upgrading_Your_Toolbox/

2018

Analysis of manufacturing costs for conventional gear manufacturing processes: a case study of a spur engine gear
Conference Paper ·Gears Conference 2018, At Lyon, France, September 2018 

2019

Research Article | Open Access
Volume 2019 |Article ID 7043604 | 17 pages | https://doi.org/10.1155/2019/7043604
Research Methods and Applications of Gear Manufacturing Process Optimization
Qiang Li, Liyang Xie  , Jiaxin Song, Haiyang Li, and Guoliang Xu
https://www.hindawi.com/journals/mpe/2019/7043604/