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Spiral Bevel Gear Manufacturing rev 1

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Firdaus Jahari
Firdaus Jahari

This document outlines the process of manufacturing a spiral bevel gear using CAD/CAM technology. The key steps include: 1. Measuring an existing bevel gear to obtain its dimensions. 2. Creating a CAD model of the gear in Catia software. 3. Programming the machining processes for turning and milling in Catia CAM. This includes simulating the processes. 4. Generating G-code from the CAM program to machine the gear using a lathe and milling machine. 5. Machining the gear prototype using the generated G-code on the machines. The overall goal is to expose a student to the CAD/CAM workflow for designing and

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Spiral Bevel Gear Manufacturing By: Mohd Firdaus B Jahari For: Dr. -Ing Yupiter Manurung Prof. Dr.-Ing. Bernd Schwarze
Content 1.0 Introduction 2.0 Objective 3.0 Scope of project 4.0 Research Methodology 4.1 First phase: Bevel Gear Measurement Process 4.2 Second phase: CAD modeling of the bevel gear 4.3 Third phase: CAM programming 4.3.1 The turning process 4.3.2 The milling Process 4.4 Fourth phase : G-code generation 4.5 Fifth phase : Machining Process 5.0 Conclusion 6.0 Recommendation
1.0 Introduction ï‚— Nowadays bevel gear was produced by using gear manufacturing machines. ï‚— 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 ï‚— to machined a spline teeth bevel gear using a NC lathe machine and universal milling machine. ï‚— To exposed the student with the CAD CAM working environment ï‚— 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. ï‚— To produce a g-code/a machining program to be used as the machining instruction. ï‚— 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 ï‚— In this process, the gear is measured to get its dimension. ï‚— 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 ï‚— 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 ï‚— the machining program of the bevel gear are programmed using bevel gear CAD model.
4.3.1 The turning process ï‚— 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 ï‚— The milling process is purposely done to form the teeth of the gear. ï‚— 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
Spiral Bevel Gear Manufacturing rev 1
4.4 Fourth phase : G-code generation ï‚— In the fourth phase of the project, the NC code of the machining process is generated using Catia.
4.5 Fifth phase : Machining Process ï‚— The final phase of the project is the machining process where the bevel gear are machined using the turning and milling machine. ï‚— The first machining process was done by using the Monforts NC lathe machine equipped with Monfort controller. ï‚— The gear tooth machining was done using the DMG DMU 60 universal milling machine equipped with Heidenhain iTNC 530 controller.
5.0 Conclusion ï‚— The objective of The Research Assistant Program is successfully achieved. ï‚— Student is exposed to the working environment and more prepared to the challenging world of the industry. ï‚— The student is now more skillful in doing CAD drawing and CAM programming. ï‚— the student was able to learn a lot of new thing about CADCAM system ï‚— the student will be exposed to the actual machining process. ï‚— The student also exposed to the method of selecting tools and setting the variable of the machining through this project. ï‚— 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 ï‚— measuring projector should be used to measure the gear to get a more accurate dimension. ï‚— 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

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Spiral Bevel Gear Manufacturing rev 1

  • 1. Spiral Bevel Gear Manufacturing By: Mohd Firdaus B Jahari For: Dr. -Ing Yupiter Manurung Prof. Dr.-Ing. Bernd Schwarze
  • 2. Content 1.0 Introduction 2.0 Objective 3.0 Scope of project 4.0 Research Methodology 4.1 First phase: Bevel Gear Measurement Process 4.2 Second phase: CAD modeling of the bevel gear 4.3 Third phase: CAM programming 4.3.1 The turning process 4.3.2 The milling Process 4.4 Fourth phase : G-code generation 4.5 Fifth phase : Machining Process 5.0 Conclusion 6.0 Recommendation
  • 3. 1.0 Introduction ï‚— Nowadays bevel gear was produced by using gear manufacturing machines. ï‚— This project objective is to create a new method to produce spiral bevel gear using a NC lathe machine and universal milling machine.
  • 4. Figure 1: Gear manufacturing machines
  • 5. 2.0 Objective ï‚— to machined a spline teeth bevel gear using a NC lathe machine and universal milling machine. ï‚— To exposed the student with the CAD CAM working environment ï‚— 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. ï‚— To produce a g-code/a machining program to be used as the machining instruction. ï‚— To develop a manual for future references.
  • 6. 3.0 Scope of project ï‚— The scope of this project is to produced a spline bevel gear using the CADCAM technology. ï‚— Catia was used as the CADCAM software to develop the CAD model of the gear. ï‚— Catia also used to program the machining process and to generate the NC/G – code of the machining. ï‚— Catia is also used to simulate the machining process to make sure there is no collision occurred. ï‚— The post proccessor used to produce the G-code is HDH 426 3X. ï‚— The code will be transferred to the machine by using HMI software and LAN cable. ï‚— 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. ï‚— The material that will be used is PP/PE as a prototype.
  • 7. Figure 2 :The spline bevel gear
  • 8. Figure 3 :Monfort Lathe machine
  • 9. Figure 4 :Deckel Maho DMU 60 universal milling machine
  • 10. 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
  • 11. 4.1 First phase: Bevel Gear Measurement Process ï‚— In this process, the gear is measured to get its dimension. ï‚— The measuring tools used in the measurement process are a vernier caliper and a ruler.
  • 12. Figure 5 :Dimension of the bevel gear
  • 13. 4.2 Second phase: CAD modeling of the bevel gear using ï‚— The second phase of this project is the modeling of the bevel gear using CAD software.
  • 14. Figure 6 :The bevel gear CAD model
  • 15. 4.3 Third phase: CAM programming ï‚— the machining program of the bevel gear are programmed using bevel gear CAD model.
  • 16. 4.3.1 The turning process ï‚— 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.
  • 17. Figure 7 :The turning product
  • 18. 4.3.2 Milling Process ï‚— The milling process is purposely done to form the teeth of the gear. ï‚— This is because of the angle of the gear teeth that makes it impossible to be machined with 3 axis machine.
  • 19. Figure 8 :The machining of the gear tooth
  • 21. 4.4 Fourth phase : G-code generation ï‚— In the fourth phase of the project, the NC code of the machining process is generated using Catia.
  • 22. 4.5 Fifth phase : Machining Process ï‚— The final phase of the project is the machining process where the bevel gear are machined using the turning and milling machine. ï‚— The first machining process was done by using the Monforts NC lathe machine equipped with Monfort controller. ï‚— The gear tooth machining was done using the DMG DMU 60 universal milling machine equipped with Heidenhain iTNC 530 controller.
  • 23. 5.0 Conclusion ï‚— The objective of The Research Assistant Program is successfully achieved. ï‚— Student is exposed to the working environment and more prepared to the challenging world of the industry. ï‚— The student is now more skillful in doing CAD drawing and CAM programming. ï‚— the student was able to learn a lot of new thing about CADCAM system ï‚— the student will be exposed to the actual machining process. ï‚— The student also exposed to the method of selecting tools and setting the variable of the machining through this project. ï‚— 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.
  • 24. 6.0 Recommendation ï‚— measuring projector should be used to measure the gear to get a more accurate dimension. ï‚— 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.
  • 25. Q & A