Chapter 42 Thread and Gear Manufacturing THREAD MANUFACTURING SCREW THREAD STANDARDS 10/16/2014. MET Manufacturing Processes.
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1 MET Manufacturing Processes Chapter 42 Thread and Gear Manufacturing Before you begin: Turn on the sound on your computer. There is audio to accompany this presentation. THREAD MANUFACTURING Screw Thread Ridge of uniform section in the form of a helix on the external or internal surface of a cylinder (straight thread) or in the form of a conical spiral on the frustum of a cone (taper thread). Chapter 42-2 SCREW THREAD STANDARDS Unified and American Screw Thread Standards (1948) H28 Handbook adopted by U.S., Canada, and Great Britain. International Organization for Standards (1968) ISO/R , metric standards Chapter
2 SCREW THREAD STANDARDS Chapter 42-4 NOMENCLATURE 1. Pitch distance from a point on one screw thread to the corresponding point on the next thread. 2. Threads per Inch TPI = 1 pitch 3. Pitch Diameter diameter at which thread form width equals thread form separation. Chapter 42-5 NOMENCLATURE Pitch Diameter Pitch Line Pitch Chapter
3 NOMENCLATURE 4. Major Diameter: External crest Internal root 5. Minor Diameter: External root Internal crest Chapter 42-7 NOMENCLATURE 6. Lead axial advance of thread per revolution. Lead = pitch for single lead thread. 7. Root usually radius to relieve stress. 8. Helix Angle angle of thread form from perpendicular to axis. 9. Thread Angle included angle of thread form. Chapter 42-8 NOMENCLATURE Chapter
4 NOMENCLATURE 10. Class manufacturing tolerances: Class 1 special applications (ordnance) Class 2 normal production grade Class 3 minimum clearance 11. Designator: A external thread B internal thread Chapter NOMENCLATURE ¼ - 20 UNC 3A Nominal Size Threads per Inch Thread Series Thread Class Chapter TYPES of SCREW THREADS 1. Coarse-thread series (UNC and NC) - general use. 2. Fine-thread series (UNF and NF) - automotive and aerospace. 3. Extra-fine-thread series (UNEF and NEF) - thin wall. 4. Eight-thread series (8UN and 8N) pipe flanges, 1 to 6 inch diameter. 5. Twelve-thread series (12UN and 12N) - not used extensively, 1/2 to 6" diameter. 6. Sixteen-thread series (16UN and 16N) - fine thread applications, 3/4 to 6" diameter. Chapter
5 TYPES of SCREW THREADS 7. American Acme thread - used to transmit power and motion. 8. Buttress thread - used to transmit power and motion. 9. Square thread - used to transmit power and motion Worm thread - used to transmit power and motion. 11. American standard pipe thread - taper thread form. Chapter TYPES of SCREW THREADS Chapter External Threads 1. Single point threading on lathe manual or CNC 2. Thread die solid or solid-adjustable, usually hand threading 3. Die head self-opening used on lathes and screw machines Chapter
6 Chapter Chapter Chapter
7 Chapter External Threads (continued): 4. Thread milling CNC machines 5. Thread grinding single or multiple form wheels 6. Thread rolling cold forming process, flat or cylindrical dies Chapter Chapter
8 Chapter Chapter Chapter
9 THREAD ROLLS Chapter THREAD ROLLING Chapter Chapter
10 Internal Thread Variations Chapter Internal Threads 1. Tapping hand, drill press, lathe, and CNC equipment Taper tap (8) tapered (incomplete) threads for alignment. Plug tap (4) tapered threads. Bottoming tap (1 1/2) tapered threads. Straight or spiral flute Controls direction of chip flow. Standard point or spiral point Controls direction of chip flow. Chapter Chapter
11 Chapter Chapter Chapter
12 Chapter Chapter Chapter
13 Tapping Heads: Chapter Internal Threads (continued): 2. Collapsing taps similar to die head. 3. Single point threading on lathe boring bar. 4. Thread milling CNC machines. 5. Thread forming fluteless taps. Chapter Chapter
14 Chapter Tap Drill Calculation: TD = MD [ 2(d) x 0.75 ] where: TD = Tap Drill Diameter MD = Major Diameter d = Thread Depth = P x P = Pitch = 1/TPI TPI = #Threads per Inch Chapter Example Tap Drill Calculation: ¼-20 UNC-3B thread TD = MD [ 2(d) x 0.75 ] d = P x P = 1/TPI TD = [2(1/20)(0.6134) x 0.75] TD = (#6 Drill) Chapter
15 T m (L AL A R)n πd(l AL A R)n N 12V Where: T m = Cutting Time (min) L = Depth of Tapped Hole (in) n = Threads per Inch N = Spindle Speed (rpm) D = Tap Diameter (in) V = Cutting Speed (sfpm) A L = Start Allowance (in) A R = Withdraw Allowance (in) Chapter Gear Manufacturing Chapter INTRODUCTION Gears Transmit power and motion mechanically. Size range Microscopic to 30+ ft in diameter. Chapter
16 TYPES of GEARS 1. Spur Gears straight teeth, parallel shafts. 2. Helical Gears tooth form at angle to axis of rotation, parallel and nonparallel shafts. 3. Rack gear with infinite radius, teeth lie on straight line. 4. Herringbone Gears double helix angle. Continuous no center relief. Modified groove or gap between helix pairs. Chapter TYPES of GEARS 5. Worm and Worm Gear type of screw thread in mesh with special gear tooth form. 6. Bevel Gear teeth form on conical form, straight or spiral-tooth. 7. Hypoid Gear spiral bevel gear not requiring common intersecting axes. 8. Zerol Gear bevel gear with teeth in circular arc. 9. Crown Gear tooth form in side of disk. Chapter TYPES of GEARS Chapter
17 TYPES of GEARS Chapter NOMENCLATURE 1. Pitch Circle - corresponds to effective diameter of gear, controls angular velocity. 2. Pitch Diameter (PD) - pitch circle diameter. 3. Pitch Point - point of intersection between gears in mesh, should be on pitch circle. 4. Involute Curve - Gear tooth form. Allows rolling motion rather than sliding motion. Chapter NOMENCLATURE Chapter
18 NOMENCLATURE INVOLUTE CURVE Chapter NOMENCLATURE 5. Diametrical Pitch (DP) number of teeth (N) per unit of pitch diameter (PD): DP = N/PD 6. Addendum radial distance from PD to outside diameter: Addendum = 1/DP. 7. Dedendum radial distance from PD to root circle. 8. Circular Pitch distance between corresponding points on adjacent teeth. Circular Pitch = /DP Chapter NOMENCLATURE Chapter
19 NOMENCLATURE 9. Tooth Thickness - measured along pitch circle. 10. Face Width length of teeth in axial plane. 11. Tooth Face mating surface between pitch circle and addendum circle. 12. Tooth Flank mating surface between pitch circle and root circle. Chapter NOMENCLATURE Chapter Machining - multi-step process. 2. Cold-Forming - rolling process similar to thread method. 3. Extrusion 4. Casting - sand, die and investment casting used. 5. Blanking - punch press. 6. Powder Metallurgy - high quality. 7. Plastic Molding 8. Forging 9. Flame Machining Chapter
20 MANUFACTURING SEQUENCE 1. Blanking produces a semi-finished form ready for the gear cutting operation. Methods: Turning. Milling. Grinding. Chapter MANUFACTURING SEQUENCE 2. Gear Cutting forms gear tooth form. Methods: Hobbing Generating process. Hob has one tooth form wrapped around cylinder to form helix. Most common gear manufacturing process. Milling Form cutters with tooth shape utilized. Stocking cutter used for roughing cuts. Helical gears milled using dividing head. Special milling machines available. Chapter HOBBING Chapter
21 HOBBING Chapter HOBBING Chapter HOBBING Chapter
22 HOBBING Chapter MILLING Chapter MILLING Chapter
23 MILLING Chapter MILLING Chapter MILLING Chapter
24 MANUFACTURING SEQUENCE 2. Gear Cutting (continued) Methods: Shaping Generating process. Reciprocating cutter in form of tooth shape. Broaching Both internal and external gears. Bevel Gear Utilizes special machines. Rolling Cold-forming process. Grinding Wheels dressed into tooth form. Chapter SHAPING Chapter SHAPING Chapter
25 SHAPING Chapter SHAPING Chapter BROACHING Chapter
26 BROACHING Chapter SPECIAL MACHINES Chapter GRINDING Chapter
27 GRINDING Chapter GRINDING Chapter MANUFACTURING SEQUENCE 3. Heat Treatment required for wear, through hardening and surface hardening used. 4. Finishing Finalize geometry and accuracy. Methods: Shaving Gear run at high speed in contact with shaving tool. Minimal stock removed. Roll Finishing Cold-forming process for helical gears. Grinding Wheel dressed with tooth form or straight wheel with gear rolling past. Lapping Cast iron lapping gear. Chapter
28 FINISHING Chapter The End See Oncourse for Videos Chapter
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