Volume 02 Issue 11-2022
127
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
02
I
SSUE
11
Pages:
127-130
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
METADATA
IF
–
7.356
A
BSTRACT
This article discusses the manufacture of gears with two methods (copy method and run-in method). The
largest number of gear wheels are made of carbon and alloy steels, and less often of cast iron, bronze and
plastic. In the manufacture of gears, two fundamentally different methods are used. copy method and run
method. Gears, especially high-precision gears, must have dimensional stability, therefore, in their
manufacture, high requirements are placed on material homogeneity and balance of internal stresses.
K
EYWORDS
Gear manufacturing, high-precision, material homogeneity, copying method, running-in method, tooth
profile, initial contour, gearing, involute curvature radius, tooth shape change.
I
NTRODUCTION
The largest number of gear wheels are made of
carbon and alloy steels, and less often of cast iron,
bronze and plastic.
Gears, especially high-precision ones, must have
dimensional stability, therefore, in their
manufacture, high requirements are placed on
Journal
Website:
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Copyright:
Original
content from this work
may be used under the
terms of the creative
commons
attributes
4.0 licence.
Research Article
METHODS OF MANUFACTURING GEARS
Submission Date:
November 05, 2022,
Accepted Date:
November 15, 2022,
Published Date:
November 30, 2022
Crossref doi:
https://doi.org/10.37547/ijasr-02-11-19
Bakhtiyar Tilavaldiev
Senior Lecturer, Fergana Polytechnic Institute, Fergana, Uzbekistan
Volume 02 Issue 11-2022
128
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
02
I
SSUE
11
Pages:
127-130
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
METADATA
IF
–
7.356
material homogeneity and balance of internal
stresses [1,2,3,4]. It is most expedient to use in the
manufacture of alloy steels, which warp less
compared to carbon steels. For example, in the
manufacture of wheels of the 5th ... 6th degree of
accuracy, steels 20X, 12XNZA, 25XGT (heat
treatment,
nitrocarburizing),
18XGT
(carburizing), 40X and 40XFA (hardening) are
used. Carbon steels (steel 15, 20) are carburized,
and steels 40, 45 are hardened [5,6,7,8,9].
The main part
In the manufacture of gears, two fundamentally
different methods are used. Copy method and run
method.
Copy Method
With this method, the profile of the tool (disk or
finger cutter) follows the profile of the cavity of
the cutter wheel.
As a method of cutting wheels, it has significant
drawbacks - relatively low productivity and
accuracy; the need to have a large number of tool
sizes for cutting various wheels (the tool itself has
a complex shape); the need to have an additional
dividing device on the machine, and others.
Therefore, this method is used very rarely when
cutting gears (used mainly in repair production)
[10,11,12].
Run-in method (envelope)
With this method, the tool is, as it were, involute
gear, which has a cutting edge and is made of
appropriate tool steel.
When cutting the wheel, in addition to the cutting
motion, the tool and the workpiece are given a
rolling motion, i.e. movement that simulates the
operation of two gear wheels in engagement. In
this case, the required number of teeth with an
involute profile is automatically formed on the
cutter wheel. In this case, the tooth profile is
formed not as a copy of the tool profile, but as an
envelope with too many positions. Significantly
increased productivity (because the process is
continuous) and accuracy (because there is no
additional dividing device). The necessary
nomenclature of the tool is sharply reduced, tk.
one and the same tool can cut the wheel of this
module with any number of teeth [13,14,15].
A toothed rack with a straight tooth profile is a
special case of an involute wheel, therefore, with
the rolling method, it is the most often rack type
tool used(a tool that has the shape of a gear rack
in an axial section). It can be a toothed comb or a
worm cutter, which is used most often. This
dramatically simplifies the shape of the tool and
its manufacture. The standard gear rack
underlying the tool is called generating initial
contour.
Since the tool tooth head forms the tooth root of
the cut wheel, the height of the head of the
generating initial contour is made following the
height of the tooth root of the usual initial
contour, i.e., the generating initial contour has a
tooth symmetrical in height concerning the
dividing line.
To increase the tool life, the cutting edge of the
tooth at the top has a rounding. The amount of
Volume 02 Issue 11-2022
129
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
02
I
SSUE
11
Pages:
127-130
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
METADATA
IF
–
7.356
rounding is determined by the height factor of the
rounded area h_k*=0.25.
Another significant advantage of the rolling
method is that with the same tool, on the same
machine (at no additional cost), it is possible to
use different parts of the involute for profile
formation on wheels with the same number of
teeth, significantly changing the shape of the teeth
and the properties of the wheels and gears
[14,15,16]. This is achieved by changing the
position of the tool relative to the workpiece
when cutting the wheel (Fig. 1).
Fig.1. Machine engagement.
Figure 1 shows the machine engagement of the
generating initial contour with a cut wheel (rack
and pinion engagement).
In this case, the engagement line is tangent to the
main circumference of the cut wheel and
perpendicular to the rack tooth profile. The point
of its intersection with the centre line (in this
case, the centre line is a straight line passing
through the centre of the wheel and
perpendicular to the dividing straight line of the
rack) is the engagement pole W, through which
the initial circle of the cut wheel passes in
machine engagement.
The straight line of the rack, tangent to the initial
circle of the wheel at the pole of engagement, is
the initial straight line. Since the initial straight
line during the cutting process rolls without
slipping along the initial circle of the wheel (the
initial lines are centroids in relative motion), then
all dimensions from the initial straight line to the
true value are transferred to the initial circle of
the wheel being cut, including the pitch.
Volume 02 Issue 11-2022
130
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
02
I
SSUE
11
Pages:
127-130
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
METADATA
IF
–
7.356
The step on the initial straight rail is the standard
value, which should be on the pitch circle of the
wheel. Therefore, when engaging with a standard
rail, the pitch circle of the wheel always acts as the
starting circle, and the engagement angle is equal
to the standard profile angle of the initial contour
(αw=α = 20°).
The position of the tool is characterised bias
factor "x":
the displacement is considered zero (x=0)
if during cutting the pitch line of the rack touches
the pitch circle of the wheel (coincides with the
initial straight rail);
the offset is positive (x>0) if the pitch line
passes outside the pitch circle of the cut wheel
(the tool moves away from the centre of the
workpiece - this is the case shown in Figure 1);
with a negative offset, the tool approaches
the centre of the workpiece, and the pitch line of
the rack intersects the pitch circle of the wheel.
Figure 2 shows how the shape of the tooth
changes with a change in the displacement factor.
Rice. 2. Changing the shape of the tooth.
It can be seen from the figure that the same
evolvent is formed in all cases. When changing the
position of the tool, the section of this involute
used for the tooth profile changes. As the
displacement factor increases, the tooth becomes
thicker, more rigid, and more bending-resistant.
An increase in the radii of involute curvature in
higher sections also leads to an increase in the
contact strength of the teeth. The use of a negative
offset allows you to reduce the dimensions of the
cut wheels.
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Volume 02 Issue 11-2022
131
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
02
I
SSUE
11
Pages:
127-130
SJIF
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FACTOR
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5.478
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5.636
)
METADATA
IF
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