PNG UNIVEERSITY OF THECNOLOGY

DEPARTMENT OF MECHANICAL
ENGINEERING

Friday-27-08-2021

MILLING MACHIN LAB

REPORT 2
SPUR
GEAR

Ph.D., DR K.MUDULI (sub-lecturer)

Ph.D. DR Mohamed (associate)
 Abstract:
Horizontal Milling machines (HMM), are used in metal machine which uses varies cutting processes to produce
metal work (job) that requires higher dimensional accuracy, surface finish and prolong to life when in service.
This article provides information about the different cutting processes used in milling machine to produce
gears, specifically spur gear. Important calculations and indexing method that are required to attain desired
gear dimensions surface finish and strength for a specific application. Also important factors that affect
performance of cutting tool, machine and more importantly the gear that is to be manufactured.
Introduction
Spur gears are one of the most popular types of precision cylindrical gears. These gears feature a simple
design of straight, parallel teeth positioned around the circumference of a cylinder body with a central bore
that fits over a shaft.

Used widely in mechanical applications to increase or

decrease the speed of a device or multiply torque by
transmitting motion and power from one shaft to
another through a series of mated gears. Thus spur
gears play a vital roll in most industrial mechinary,
automotion to do work efficiantly. Therefore, special
concideration a taken in designing and manufacturing
gears wich will be further discused in this report.

Formost, it is very important to understand the

different parts and function of a HMM and the
Fig.1 Mated Spur Gear-
sequence of wich various cutting opparations are and power
Transmits motion
peformed. Particularly for this report, the
manufacturing process of spur gear using blank mild-
steel.

AIM:

To use different cutting operations in a HMM to manufacture a 28 tooth

spur gear, ratio is 40:1, from a cylindrical black with dimensions 50mm
diameter x 20mm thickness. Also identify the important factors that will
influence both the performance of cutting tool and working peace such
as feed, velocity of cutting tool (life) and environment at which efficiency
cutting gear tooth will be at maximum producing desired gear dimensions. Fig 2. Spur-Gear

Material:

1. Mild Steel Round Dia 60 mm X 20 mm Thickness

2. Spur Gear cutter- Gear cutter are evaluated based on the 15.50 degrees
pressure angle that are made of eight different forms (number 1-8) for
each pitch depending upon the number of teeth for which the cutter is

1 Fig 3 Cutting tool. No.4, M2mm

 to be pushed. For this case we use Ranging from 26-34 teeth we use cutting tool No. 4. That is to
ensure accuracy in tooth dimensions.
3. Cutting Fluid

Tools required:
1. Vernier caliper,
2. Gear tooth Vernier,
3. Indexing attachment.
4. Horizontal Milling machine

Fig 4. Indexing attachment.

Head.

Sequence of
Operations:
On the Milling machine, a circular rod was calibrated to the dimensions required to create the gear blank. At the
face center of the turning bar a hole of 15mm was drilled to the desired depth. From the bar a blank of 25mm
width and 81mm external diameter and 15mm cut off by parting method. A high speed steel cutter was selected
for spur gearing of module 2mm. At the dead center and dividing head center of the milling machine the gear
blank was fixed in between. A 49 holes index plate was selected and placed/fixed in the dividing head. Now the
milling machine table was elevated by elevating screw and work peace approaching the cutter. Ensuring the
alignment of the gear blank and the cutter (fig.5), corresponds to table moment limits for both transverse and
cross feed. Select suitable cutting speed of m/mm, shifting speed lever and
feed lever of the milling machine in milling head. Inspect direction of
cutting tool with respect to work piece when switching on the machine.
The gear blank was fed manually by table against rotating high-speed steel
cutter giving depth of cut (gear tooth).
The gear black was moved away from the cutter after completing each
tooth.
Using simple indexing method, calculations where adapted producing
equal number of visions that are being cut on gear blank (fig 6).
Fig 5. Alignment Now move the sector arm of the
of Cutter & Blank dividing head to the next point and rotate the
crank of dividing head to the desired number
of rotation and move the crank pin on desired number of holes of the index
plate to exact number of equal division on the gear blank. Again the gear
blank is fed on the rotating cutter and second teeth are completed by
following indexing procedure. Supply suitable cutting fluids at the time of
machining and wear safety devises while machining is going on. During
machining process, safety glasses where used along with other safety
Fig 6. Indexing gear tooth
measures also considered.
2
 Observations & Calculation:
No. of Teeth cut on gear blank is (N) = 28

Blank diameter = (N +2) M = (28+2)*2=60 mm

Simple indexing
40 40 21
No. of turns of index crank= N = 28 = 1 49
Depth of cut = 2.25 X M; M = Module = 2mm
Tooth depth = 2.25 X 2 = 4.5mm

Results
Lab was successfully completed with desired results and better practical understanding of metal cutting
generally. The speed of cutting tool and the cutting tool chosen was standardized (referencing) according to
desired parameters of the spur gear influenced by the number of teeth and dimensions required for specific
job application.
Moreover, the environment (cutting fluid), which is a paramount aspect in cutting process to attain better
surface finish on job also prolong tool life and increase overall efficiency of MM and work output(reference
lecture notes), was not available due technical or mechanical faults in the MM at the time.
Also simple indexing method was found convenient method for desired spur gear the lab aims to achieve
apart from other indexing methods available. However due to limited time in the workshop, the 28 tooth spur
gear was not produced due to the lengthy process that requires repeated number of indexing for every tooth
to be cut. Thus, the aim can be achieved if given enough time prior to the cutting process. Over all calculations
are direct for important parameters stated above
Discussion
As observed during the lab session, the MM is a precision cutting machine designed to produce and meet
highest of engineering and consumer demands. There are new developments to the MM systems such as
Automated MM (AMM), CNC and etc. specially designed to increase efficiency and productivity with respect to
increasing demands. Economical, yet time saving and easy to use.
As stated by the lab invigilators, the MM that was available to us in
the workshop was outdated, having limitations, compared to update
MM that are now available. However, regardless of the limited
resources, with the help of experienced lab instructors, the basic
underlying concept of spur gear cutting processes in the MM was
convoyed together with practical knowledge of the manufacturing
process.
Recommendation CNC MILLING MACHINES

3
The MM we have available in the lab had no fluid cutting element which one of the important factors to apply
in such cutting process. Thus spur gears are widely used in dynamic loading and poor surface finishing due to
the lack of cutting fluid might instigate a fatigue when work peace is in working condition. This could lead to
mechanical failures that can be very costly and damaging. However in such case, manually applying cutting
fluid when in operation is possible ensuring safety distance and measures are taken strictly.
However, the overall working conditions of the MM was at its maximum. The instructors had been resourceful
throughout the lab regardless of the limited time available. It is through actual practice over time and
experience to acquire a perfect spur gear from the HMM.
CONCLUSION