Spiral Bevel Gear Manufacturing

By:Mohd Firdaus B Jahari

For:Dr. -Ing Yupiter Manurung

Prof. Dr.-Ing. Bernd Schwarze

Content

1.0 Introduction2.0 Objective3.0 Scope of project4.0 Research Methodology

4.1 First phase: Bevel Gear Measurement Process4.2 Second phase: CAD modeling of the bevel gear4.3 Third phase: CAM programming

4.3.1 The turning process 4.3.2 The milling Process

4.4 Fourth phase : G-code generation4.5 Fifth phase : Machining Process

5.0 Conclusion6.0 Recommendation

1.0 Introduction

Nowadays bevel gear was produced by using gear manufacturing machines.

This project objective is to create a new method to produce spiral bevel gear using a NC lathe machine and universal milling machine.

Figure 1: Gear manufacturing machines

2.0 Objective

to machined a spline teeth bevel gear using a NC lathe machine and universal milling machine.

To exposed the student with the CAD CAM working environment

To exposed the student on the basic of selecting tools and right variable such as spindle speed and federate to suit the machining process and the machine itself.

To produce a g-code/a machining program to be used as the machining instruction.

To develop a manual for future references.

3.0 Scope of project

The scope of this project is to produced a spline bevel gear using the CADCAM technology.

Catia was used as the CADCAM software to develop the CAD model of the gear.

Catia also used to program the machining process and to generate the NC/G – code of the machining.

Catia is also used to simulate the machining process to make sure there is no collision occurred.

The post proccessor used to produce the G-code is HDH 426 3X. The code will be transferred to the machine by using HMI software and

LAN cable. The machines that will be used are the Monforts NC lathe machine

equipped with Monfort controller and Deckel Maho DMG DMU 60 equipped with heidenhain iTNX 530 controller.

The material that will be used is PP/PE as a prototype.

Figure 2 :The spline bevel gear

Figure 3 :Monfort Lathe machine

Figure 4 :Deckel Maho DMU 60 universal milling machine

4.0 Research Methodology

Measure the dimension of the bevel gear

Drawing process of the CAD model of the bevel gear

Machining process programming and simulation

G-code generation

Actual machining process

4.1 First phase: Bevel Gear Measurement Process

In this process, the gear is measured to get its dimension.

The measuring tools used in the measurement process are a vernier caliper and a ruler.

Figure 5 :Dimension of the bevel gear

4.2 Second phase: CAD modeling of the bevel gear using

The second phase of this project is the modeling of the bevel gear using CAD software.

Figure 6 :The bevel gear CAD model

4.3 Third phase: CAM programming

the machining program of the bevel gear are programmed using bevel gear CAD model.

4.3.1 The turning process

For the turning process, another cad model was drawed (product1).The cad model dimension is the same with the bevel gear except that it have no cavity at where the teeth reside.

Figure 7 :The turning product

4.3.2 Milling Process

The milling process is purposely done to form the teeth of the gear.

This is because of the angle of the gear teeth that makes it impossible to be machined with 3 axis machine.

Figure 8 :The machining of the gear tooth

4.4 Fourth phase : G-code generation

In the fourth phase of the project, the NC code of the machining process is generated using Catia.

4.5 Fifth phase : Machining Process

The final phase of the project is the machining process where the bevel gear are machined using the turning and milling machine.

The first machining process was done by using the Monforts NC lathe machine equipped with Monfort controller.

The gear tooth machining was done using the DMG DMU 60 universal milling machine equipped with Heidenhain iTNC 530 controller.

5.0 Conclusion

The objective of The Research Assistant Program is successfully achieved.

Student is exposed to the working environment and more prepared to the challenging world of the industry.

The student is now more skillful in doing CAD drawing and CAM programming.

the student was able to learn a lot of new thing about CADCAM system

the student will be exposed to the actual machining process. The student also exposed to the method of selecting tools and

setting the variable of the machining through this project. The Research Assistant program between UITM and FH Osnabrueck

should be continued by sending another batch because of the advantages that student can harness from it.

6.0 Recommendation

measuring projector should be used to measure the gear to get a more accurate dimension.

Another project can be done based on this project.For example a research on the contact between a bevel gear and a worm can be done by using Catia software.

Q & A