Definition of Spur Gear

-a gearwheel with teeth projecting parallel to the wheel's axis.

Nomenclature of Spur Gear

Pitch surface : The surface of the imaginary rolling cylinder (cone, etc.) that the toothed gear
may be considered to replace.
Pitch circle: A right section of the pitch surface.
Addendum circle: A circle bounding the ends of the teeth, in a right section of the gear.
Root (or dedendum) circle: The circle bounding the spaces between the teeth, in a right
section of the gear.
Addendum: The radial distance between the pitch circle and the addendum circle.
Dedendum: The radial distance between the pitch circle and the root circle.
Clearance: The difference between the dedendum of one gear and the addendum of the mating
gear.
Face of a tooth: That part of the tooth surface lying outside the pitch surface.
Flank of a tooth: The part of the tooth surface lying inside the pitch surface.
Circular thickness (also called the tooth thickness) : The thickness of the tooth measured on
the pitch circle. It is the length of an arc and not the length of a straight line.
Tooth space: The distance between adjacent teeth measured on the pitch circle.
Backlash: The difference between the circle thickness of one gear and the tooth space of the
mating gear.
Backlash =Space width Tooth thickness
Circular pitch p: The width of a tooth and a space, measured on the pitch circle.
Diametral pitch P: The number of teeth of a gear per inch of its pitch diameter. A toothed
gear must have an integral number of teeth. The circular pitch, therefore, equals the pitch
circumference divided by the number of teeth. The diametral pitch is, by definition, the
number of teeth divided by the pitch diameter.
 Module m: Pitch diameter divided by number of teeth. The pitch diameter is usually specified
in inches or millimeters; in the former case the module is the inverse of diametral pitch.
Fillet : The small radius that connects the profile of a tooth to the root circle.
Pinion: The smaller of any pair of mating gears. The larger of the pair is called simply the
gear.
Velocity ratio: The ratio of the number of revolutions of the driving (or input) gear to the
number of revolutions of the driven (or output) gear, in a unit of time.
Pitch point: The point of tangency of the pitch circles of a pair of mating gears.
Common tangent: The line tangent to the pitch circle at the pitch point.
Base circle : An imaginary circle used in involute gearing to generate the involutes that form
the tooth profiles.
Line of Action or Pressure Line: The force, which the driving tooth exerts at point of contact of the two
teeth. This line is also the common tangent at the point of contact of the mating gears and is known as the
line of action or the pressure line. The component of the force along the common tangent at the p point is
responsible for the power transmission.
The component of the force perpendicular to the common tangent through the pitch point produces the
required thrust.

Pressure Angle or Angle of Obliquity (): The angle between pressure line and the common tangent to
the pitch circles is known as the pressure angle or the angle of obliquity.
For more power transmission and lesser pressure on the bearing pressure angle must be kept small.
Standard pressure angles arc and 25. Gears with 14.5 pressure angles have become almost obsolete.

Path of Contact or Contact Length: Locus of the point of contact between two mating teeth from the
beginning of engagement to the end is known as the path of contact or the contact length. It is CD in the
figure. Pitch point P is always one point on the path of contact. It can be subdivided as follows:
Path of Approach: Portion of the path of contact from the beginning of engagement to the pitch point, i.e.
the length CP.
Path of Recess: Portion of the path of contact from the pitch point to the end of engagement i.e. length PD.
Arc of Contact: Locus of a point on the pitch circle from the beginning to the
end of engagement of two mating gears is known as the arc of contact in fig. 3.22, APB
or EPF is the arc of contact. It has also been divided into sub-portions.
Arc of Approach: It is the portion of the arc of contact from the beginning of engagement to the pitch point,
i.e. length AP or EP.
Arc of Recess: Portion of the arc of contact from the pitch point to the end of engagement is the arc of
recess i.e. length PB or PF.
Angle of Action (): It is the angle turned by a gear from the beginning of engagement to the end of
engagement of a pair of teeth i.e. the angle turned by arcs of contact of respective gear wheels. Similarly,
angle of approach (a) and angle of recess () can be defined.
S=a+

Definition and Parts of Horizontal Milling Machine

- The Horizontal Milling Machine is a very robust and sturdy machine. A variety of cutters are
available to removed/shape material that is normally held in a strong machine vice. This
horizontal miller is used when a vertical miller is less suitable. For instance, if a lot of material
has to be removed by the cutters or there is less of a need for accuracy - a horizontal milling
machine is chosen.

The cutter can be changed very easily. The arbor bracket is removed by loosening nuts and bolts that
hold the arbor firmly in position. The arbor can be slid off the over arm. The spacers are then removed
as well as the original cutter. The new cutter is placed in position, spacers slid back onto the arbor and
the arbor bracket tightened back in position.

Definition and Parts of Indexing Head

-An indexing head, also known as a dividing head or spiral head, is a specialized tool that allows
a work piece to be circularly indexed; that is, easily and precisely rotated to preset angles or
circular divisions. Indexing heads are usually used on the tables of milling machines, but may be
used on many other machine tools including drill presses, grinders, and boring machines.
Common jobs for a dividing head include machining the flutes of a milling cutter, cutting the
teeth of a gear, milling curved slots, or drilling a bolt hole circle around the circumference of a
part.

What is Indexing plate?

A plate perforated with rows of different numbers of equally spacedholes as a
guide for indexing work.

Procedure of Gear Cutting

Gear cutting is any machining process for creating a gear. The most common
gear-cutting processes include hobbing, broaching, milling, and grinding. Such
cutting operations may occur either after or instead of forming processes such
as forging, extruding, investment casting, or sand casting.

Gears are commonly made from metal, plastic, and wood. Although gear cutting
is a substantial industry, many metal and plastic gears are made without
cutting, by processes such as die casting or injection molding. Some metal
gears made with powder metallurgy require subsequent machining, whereas
others are complete after sintering. Likewise, metal or plastic gears made with
additive manufacturing may or may not require finishing by cutting, depending
on application.

Broaching[edit]
Main article: Broaching (metalworking)
For very large gears or spline, a vertical broach is used. It consists of a vertical
rail that carries a single tooth cutter formed to create the tooth shape. A rotary
table and a Y axis are the cusomary axes available. Some machines will cut to a
depth on the Y axis and index the rotary table automatically. The largest gears
are produced on these machines.

Other operations such as broaching work particularly well for cutting teeth on
the inside. The downside to this is that it is expensive and different broach
sticks are required to make different sized gears. Therefore, it is mostly used in
very high production runs.

Hobbing
Main article: Hobbing
Hobbing is a method by which a hob is used to cut teeth into a blank. The cutter
and gear blank are rotated at the same time to transfer the profile of the hob
onto the gear blank. The hob must make one revolution to create each tooth of
the gear. Used very often for all sizes of production runs, but works best for
medium to high.

Milling or grinding
Main article: Machining
Spur may be cut or ground on a milling machine or jig grinder utilizing a
numbered gear cutter, and any indexing head or rotary table. The number of
the gear cutter is determined by the tooth count of the gear to be cut.

To machine a helical gear on a manual machine, a true indexing fixture must be

used. Indexing fixtures can disengage the drive worm, and be attached via an
external gear train to the machine table's handle (like a power feed). It then
operates similarly to a carriage on a lathe. As the table moves on the X axis,
the fixture will rotate in a fixed ratio with the table. The indexing fixture itself
receives its name from the original purpose of the tool: moving the table in
precise, fixed increments. If the indexing worm is not disengaged from the
table, one can move the table in a highly controlled fashion via the indexing
plate to produce linear movement of great precision (such as a vernier scale).
There are a few different types of cutters used when creating gears. One is a
rack shaper. These are straight and move in a direction tangent to the gear,
while the gear is fixed. They have six to twelve teeth and eventually have to be
moved back to the starting point to begin another cut.

A popular way to build gears is by form cutting. This is done by taking a blank
gear and rotating a cutter, with the desired tooth pattern, around its periphery.
This ensures that the gear will fit when the operation is finished.

Shaping
Main article: Gear shaper
The old method of gear cutting is mounting a gear blank in a shaper and using a
tool shaped in the profile of the tooth to be cut. This method also works for
cutting internal splines.

Another is a pinion-shaped cutter that is used in a gear shaper machine. It is

basically when a cutter that looks similar to a gear cuts a gear blank. The cutter
and the blank must have a rotating axis parallel to each other. This process
works well for low and high production runs.

Finishing
After being cut the gear can be finished by shaving, burnishing, grinding, honing
or lapping.