Ain Shams University.

Metal Cutting Machines and

Faculty of Engineering. Technology - MDP 384s.
Design and Production Eng. Dept. Spring 2024

Lab Report (2)

Spur Gear Cutting
(Differential Indexing)

No. Student Name Student I.D

1.
Amal Mohamed Ali 1900261
2.
Mohamed nasr mohamed rfay 2100774
3.
Mohamed mosaad 1701288
4.
Nour Mahmoud Mohamed AtTaher 1701592
5.
Mustafa rizq Abd-Elnazeer Ali 1900583
6.
Taha Ayman Mohey Aldin Hassan 1900360

Remarks: Degree:

10
 Introduction
Gear cutting on milling machines involves the process of creating gears or gear-like features
using milling cutters. This process is commonly used to produce a variety of gears, including
spur gears, helical gears, bevel gears, and worm gears.

Here's a brief introduction to gear cutting on milling machines:

1. Gear Types: Different types of gears can be cut on milling machines, including:

- Spur Gears: Straight-toothed gears that transmit motion between parallel shafts.
- Helical Gears: Gears with angled teeth that transmit motion between parallel or
non-parallel shafts.
- Bevel Gears: Gears with conical-shaped teeth used to transmit motion between
intersecting shafts.
- Worm Gears: Gears with a helical thread-like shape used to transmit motion at a
right angle.

2. Gear Milling Cutters: Specialized milling cutters are used for gear cutting, including:

- Gear Hob: A cylindrical cutter with helical teeth used for cutting spur gears, helical
gears, and splines.
- Gear Shaper Cutter: A disc-shaped cutter with tooth profiles corresponding to the
gear shape, used for cutting internal and external gears.
- Gear Milling Cutter: A multi-toothed cutter used for generating gear profiles on a
workpiece.

1|P a g e
 3. Milling Machine Setup:
Gear cutting on milling machines requires careful setup to ensure accurate results

- Mounting the workpiece securely on the milling machine table.

- Aligning the milling cutter with the workpiece to achieve the desired gear profile.
- Setting the appropriate cutting speed, feed rate, and depth of cut based on the
material and gear specifications.

4. Gear Cutting Process: The gear cutting process typically involves:

- Roughing: Removing excess material from the workpiece using roughing cuts with
the milling cutter.
- Finishing: Using finer cuts to achieve the final gear profile with precise tooth
dimensions and surface finish.
- Gear Tooth Profiling: Generating the correct tooth profile on the workpiece using the
milling cutter.

5. Control Systems: Modern milling machines may use CNC (Computer Numerical
Control) systems to automate the gear cutting process, allowing for precise control
of cutting parameters and complex gear geometries.

6. Post-Processing: After gear cutting, the workpiece may undergo additional processes
such as heat treatment, grinding, or finishing to achieve the desired mechanical
properties and surface quality .

2|P a g e
 Differential gear Indexing
The indexing method is called differential because the required division is obtained by a
combination of two movements:
1) The movement of the index crank similar to the simple indexing.
2) The simultaneous movement of the index plate when the crank is turned.
The rotation or differential motion of the index plate may take place in the same direction
as the crank or opposite to it as may be required. The result is that the actual movement of
the crank at every indexing is automatically increased or decreased giving the required index
movement of the spindle.

3|P a g e
 Calculations

Required gear specification :

• No. of gear Teeth = 79
• Module (mm)= 2
• Gear Width (mm) = 45
• Pressure angle (°) = 20
• Cutter diameter (mm) = 100
• Number of cutter teeth = 8

The available dividing head has the following specifications: -

1- One double sided index plate
No. of holes on side I: 16,17,19,21,23,29,30,31
No. of holes on side II: 33,37,39,41,43,47,49,54
2- No. of teeth of the change gears: 25,30,35,40,50,55,60,70,80,90,10

Indexing calculations:
𝟒𝟎 𝟒𝟎
𝑰= = (can not be made using simple indexing so we need to use differential indexing)
𝒁 𝟕𝟗

Assume A=80 teeth

𝟒𝟎 𝟒𝟎 𝟐𝟕
𝑰= = = For complete indexing, the index crank will have to be moved by 27 holes in
𝒁 𝟖𝟎 𝟓𝟒
57 whole circle for 78 times.

Change Gears used for differential indexing:

𝟒𝟎 𝟒𝟎 𝟐𝟓
𝑹 = (𝑨 − 𝒁) ∗ = (𝟖𝟎 − 𝟕𝟗) ∗ =
𝑨 𝟖𝟎 𝟓𝟎
So no. of teeth of change gears are 25 and 50 teeth

Gear dimensions calculations:

• 𝐷𝑏𝑙𝑎𝑛𝑘 = 𝑀 ∗ (𝑍 + 2) = 2 ∗ (79 + 2) = 162𝑚𝑚
• 𝐴𝑡 = 2.25 𝑀 = 2.25 ∗ 2 = 4.5 𝑚𝑚
• Milling cutter used is cutter no. 2

4|P a g e
 Operation and processes sheet
Sheet No.: 1 No. of Sheets: 1
AIN SHAMS UNIVERSITY-FACULTY OF ENGINEERING DEPARTMENT OF DESIGN AND PRODUCTION ENGINEERING
Name of part : Mandrel
Code : 90318000
Process Description: Turning
M/C Tool: HSS RHT
No. of M/Cs per Operator:1
Type & Size of Input Material: 402*32
high gradeSt
Total Basic Time: .62 (min.)
Time Allowance: 64 (min.)

Standard Time per Piece: 64 (min)

Main M/Cg Dims. M/Cg Speeds & Feeds

No. of Depth of Cut Setting Time Total Time
Allowance
Strokes (mm) (min.) (min.)
(mm)
Basic M/cg
No. Operation Tool Type No. of Feed Rate
Time (min.)
Initial Final Feed Cutting Revs.
M/Cg Length Run in + Run Total Stroke
Dimension Dimension (mm/rev.) Speed (rev./min.) (mm/min.)
(mm) Out (mm) Length (mm)
(mm) (mm) (mm/stroke) (m/min.) (rev./stroke
)

1 Centering 3-jaw chuck ___________________________________________________ _____ 1.5 1.5

2 Facing HSS RHT 402 400 16 4 20 1 1 1 0.05 28 300 15 1.3 1.3
3 longitudinal turning HSS RHT ∅32 ∅30 1 4 405 1 1 1 0.05 28 300 15 27 27
4 longitudinal turning HSS RHT ∅30 ∅22 100 2 102 4 1 4 0.05 18 200 10 10.2 10.2
5 longitudinal turning HSS RHT ∅22 ∅20 100 2 102 1 1 1 0.05 28 300 15 6.8 6.8
6 longitudinal turning HSS RHT ∅30 ∅22 100 2 102 4 1 4 0.05 18 200 10 10.2 10.2
7 longitudinal turning HSS RHT ∅22 ∅20 100 2 102 1 1 1 0.05 28 300 15 6.8 6.8

5|P a g e
 Sheet No.:1 No. of Sheets:1
AIN SHAMS UNIVERSITY-FACULTY OF ENGINEERING DEPARTMENT OF
DESIGN AND PRODUCTION ENGINEERING
Name of part : gear blank Group No.:
Code :002
Process Description:
Preparing gear blank to required
dimensions
M/C Tool: turning lathe
No. of M/Cs per Operator:1
Type & Size of Input Material:
Φ165 bar st37
Total Basic Time: 22min
Time Allowance: 2min

Standard Time per Piece: 24min

Main M/Cg Dims. Speeds & Feeds

No. of Basic
M/Cg Depth Feed Cutting Revs. Feed M/cg Setting Total
M/Cg Length Run in +Run Out Total Stroke No. of of Cut
No. Operation Tool Type Length(mm)
Allowance (mm/rev.) Speed (rev./min.) Rate Time Time Time
(mm) (mm) Strokes (mm)
(mm) (mm/stroke) (m/min.) (rev./stroke
) (mm/min.) (min.) (min.) (min.)

w/p fixation and 3 jaw chuck ------------------------------ 2 2

1
centering
2 Longitudinal turning Hss RHT 45 2 47 1.5 1 1.5 0.117 35 52 6.084 7.725 0.3 8

3 Drilling Twist drill Φ30 45 3 48 15 1 15 0.117 10 120 14.04 3.4 0.6 4

4 Parting off Parting off tool 81 2+2 85 5 1 5 0.117 52 100 11.7 7.264 0.8 8

6|P a g e
 Sheet No.:1 No. of Sheets:1
AIN SHAMS UNIVERSITY-FACULTY OF ENGINEERING DEPARTMENT OF
DESIGN AND PRODUCTION ENGINEERING
Name of part : spur gear Group No.:
Code :002
Process Description:
Preparing gear blank to required
dimensions
M/C Tool: universal milling machine
No. of M/Cs per Operator:1
Type & Size of Input Material:
Gear blank Φ162*45
Total Basic Time: 1324.75 min
Time Allowance: 175.25 min

Standard Time per Piece:1500 min

Main M/Cg Dims. Speeds & Feeds

No. of Basic
M/Cg Depth Feed Cutting Revs. Feed M/cg Setting Total
M/Cg Length Run in +Run Out Total Stroke No. of of Cut
No. Operation Tool Type Length(mm)
Allowance (mm/rev.) Speed (rev./min.) Rate Time Time Time
(mm) (mm) Strokes (mm)
(mm) (mm/stroke) (m/min.) (rev./stroke (mm/min.) (min.) (min.) (min.)
)
w/p fixation and Mandrel and
------------------------------ 2 2
1 indexing head
centering
2 Tooth roughing Form cutter 45 2+28+2 77 4 2 2 0.015 35 100 12 6.5 0.5 7

3 Tooth finishing Form cutter 45 2+28+2 77 0.5 1 0.5 0.005 70 220 8.8 8.75 0.5 9.25

4 indexing Indexing head 0.5 0.5

5 Repeat (2~4) for78 times 1306

7|P a g e
 Sheet No.:1 No. of Sheets:1

AIN SHAMS UNIVERSITY-FACULTY OF ENGINEERING DEPARTMENT OF DESIGN AND

PRODUCTION ENGINEERING

Name of Part: spur gear Code: Group No.:

Process Basic Time

No. Process Name Machine (min.)

1 gear blank turning Turning lathe machine 24

2 Slotting Slotting machine 4

3 Milling Universal milling machine 1500

8|P a g e
 Sheet No.: 1 No. of Sheets:1

AIN SHAMS UNIVERSITY-FACULTY OF ENGINEERING DEPARTMENT OF DESIGN AND

PRODUCTION ENGINEERING

Name of Part: spur gear Code: Group No.:

Process Basic Time

No. Process Name Machine (min.)

1 Mandrel turning Turning lathe machine 64

9|P a g e