ABSTRACT
Gears are among the most important power-transmission machine elements. This chapter first introduces readers to different types of gears with particular reference to spur gear and its nomenclature. A classification chart of gear cutting/manufacturing methods is presented, and commonly used gear cutting processes are explained; these processes include gear milling, gear broaching, gear shaping, and gear hobbing. Gear milling has been mathematically modeled so as to enable the reader to calculate the average chip thickness, the specific force with mc factored in, cutting power, and the cutting torque. Gear shaping is also analyzed to establish an expression to compute the stroke length for a shaper cutter with step cut for cutting a helical gear. Gear hobbing machines have been illustrated with particular reference to hob. Engineering analysis of gear hobbing is presented covering both single cut and double cut passes. This chapter contains 22 formulae, 10 diagrammatic illustrations, 3 MCQs, and 16 calculations/worked examples.
