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
 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.

4. Figure 1: Gear manufacturing
machines

5. 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.

6. 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.

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
 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.

12. Figure 5 :Dimension of the bevel gear

13. 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.

14. Figure 6 :The bevel gear CAD model

15. 4.3 Third phase: CAM
programming
 the machining program of the bevel gear
are programmed using bevel gear CAD
model.

16. 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.

17. Figure 7 :The turning product

18. 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.

19. Figure 8 :The machining of the gear
tooth

21. 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.

22. 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.

23. 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.

24. 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.

25. Q & A