Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
Mechanical Dept, Production Tech,BEC,BGK Page 1
INTRODUCTION TO UNIVERSAL GEAR SHAVING
MACHINE
Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
Maximum O.D
8.75" 22mm.
Pitch 4 to 16 DP 6 to 1.75 Module
Maximum Length
between centers
with standard
fixed headstock
and hydraulic *18" *457 mm.
tailstock
Maximum table
traverse at 4" 100mm.
0°
at 1.5 28mm.
90°
Cutter Centre to Min. 4.50" 114~3mm.
work centre
Max. 9.8" 249mm.
Cutter Speeds 61 to 222 r.p.m. in 14 Steps (with 9"
Cutter Head)
Table Feed Rates .623" (15.8 mm.) to 6.37" (162 mm.)
Mechanical Dept, Production Tech,BEC,BGK Page 2
TECHNICAL INFORMATION:
MACHINE GS 8"
WORK:-
Machine capacity:-
*This capacity can be increased to accommodate long shaft components.
Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
.~
Cutters:--
Maximum 9.625" 244mm. Outside
Diameter
Bore Diameter 2.500" 63.5mm.
Motors:--
Main Drive 3.5 H.P. x 1,450 r.p.m.
Knee 0.66 H.P. x 940 r.p.m.
Hydraulic 0.50 H.P. x 3,00 r.p.m.
Coolant Pump 0.66 H.P. x 1,000 r.p.m.
Clarifier Magna Drum Magnetic
Type ,
Overall Dimensions:-
Length 83" (2,108 cm.)
Width 65" (1,611 em.)
Height 81~" (2,064 cm.)
Weight 9,200 (4,173 kg.)
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
MACHINE HISTORY:
Mechanical Dept, Production Tech,BEC,BGK Page 4
••• Machine Churchill Shaver
Code GSG02
Hydraulic oil SS68
System pressure 10 bar
Type of lubricant Oil
Lubrication pressure 2bar
Coolant type R.G. Cutting Oil
Air pr 5-6 bar.
Electrical power 3 phase 415 volts
6 H.P .
C.P Value 2.19. .
Type of Hazardous
Waste generated R.G. Cutting Oil
Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
INTRODUCTION TO GEAR SHAVING
Gear shaving is the most widely used productive method of finishing spur and
helical gears following the gear cutting operation, but prior to heat treatment. It
is a cutting and not a cold working process in which metal is removed from the
gear tooth profile by a rotary cutter resembling a helical gear. Each tooth of the
cutting tool is serrated to provide a series of cutting edges.
The reasons for the wide acceptance of gear shaving as a necessary process in
the sequence of operations for producing gear are:-
Shaving is the most economical means of correcting gear cutting errors such as
index, helix angle, tooth profile, eccentricity and also improving surface finish.
Gear shaving is the most effective way of removing over stressed surface metal
because shaving cuts are light enough to remove metal without inducing further
strains .
The gear cutting process, whether hobbing or shaving, invariably cold works the
surface metal of gear teeth and includes unequal internal stains in the metal. In
the hardening process these strains are release and result in distortion which is
unpredictable in both amount and direction.
The shaving process removes this overstressed metal on the tooth surfaces, thus
heat treatment distortion results only from the inherent character of the metal
itself which can successfully be predicated and compensated.
Thus the hardened shaved gear is a finished product requiring no further
operation
Mechanical Dept, Production Tech,BEC,BGK Page 5
The work gear, mounted on an arbor between live centers, is driven and guided by the
cutter; there is no other drive connection between them, thus no dependence is placed on
the accuracy of gear trains or other mechanical elements in the shaving operation.
Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
Mechanical Dept, Production Tech,BEC,BGK Page 6
Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
Literature Survey.
Churchill Machine tool company,
The Churchill Machine Tool Company Limited began as the manufacturing
subsidiary[1] of the machine tool importers Charles Churchill & Company Limited
founded in the early 1900s by US-born Charles Churchill (1837–1916).[2] Created out of
the personal bankruptcy of Charles Churchill, the company developed to become one of
the largest British importers of machine tools from the USA and a major manufacturer of
such tools, initially under licence and later of its own development.
The original business importing American machine tools into Britain began with Charles
Churchill as sole proprietor and later as a partnership with two others. It became a
limited company in 1889. In 1906 a separate company, The Churchill Machine Tool Co
Ltd, was established with the purpose of adapting tools imported by Charles Churchill &
Co Ltd. The former expanded, producing American tools under licence and then
manufactured tools of its own design, in particular precision surface grinders and similar
engineering machinery. In 1918 The Churchill Machine Tool Co Ltd relocated its
factories onto a single site at Broadheath, near Altrincham.
The two companies initially remained closely linked, with common a chairman
and board members, including Arthur Chamberlain. In the early 1930s a series of board
disagreements within Charles Churchill & Co Ltd led to Arthur Chamberlain resigning
as chairman of that company. He remained chairman of The Churchill Machine Tool Co
Ltd and the two companies diverged. Charles Churchill & Co Ltd changed from a sales
organisation to become a manufacturer. Thereafter, both companies manufactured
machine tooling, and Charles Churchill & Co Ltd became a group of companies. By the
1960s significant rationalisation took place in British manufacturing, with companies
merging or being taken over in an attempt to achieve benefits from economies of scale
and pooled resources. The Churchill Machine Tool Co Ltd was taken over by
the Birmingham Small Arms Company; which merged with Alfred Herbert Ltd, with
production moving to Coventry. Coincidentally, Charles Churchill & Co Ltd was taken
over by Tube Investments (TI).
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
The Churchill Machine Tool Co Ltd ceased trading in the early 1970s along with several
other companies in the Alfred Herbert group, during a period of huge contraction of the
manufacturing sector in Britain's economy. A part of the Charles Churchill & Co Ltd
group became Matrix Churchill through a convoluted corporate process.
History:
Charles Churchill,
Charles Churchill was born in the United States, in Hamden, Connecticut, on 8 July
1837.[3] His father was Willis Churchill, described as "a mechanic of rare ability, original
in the style of his goods and in his process of manufacture", [4] who had been
manufacturing brass surgical instruments at a time when such instruments were all
imported to the US. Willis Churchill founded a factory manufacturingauger drill bits
which was so locally prominent that the area of Hamden in which it was situated was
called Augerville.[5]
Charles Churchill, 1837–1916
Charles worked in his father's auger manufacturing business but when Willis went to
London in 1861 to supervise the installation of wire-covering machinery being exported
by Thompson, Langdon & Co of New York City, Charles soon followed and, once there,
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
spotted a business opportunity for himself as he saw the interest that the US-made
equipment generated. By the time of his death his businesses had a presence in
London, Manchester, Glasgow, Birminghamand Newcastle-on-Tyne and was "a giant
machine-importing business".[6]
Gear shaping.
Gear shaping is a machinery process for generating teeth by a corresponding
cutter. Gear shaping has become a convenient operation and one of the most versatile of
all gear cutting operations.
Shaping a gear.
The types of cutters used for gear shaping can be grouped into about four categories:
disk, hub, shank, and helical cutters. The cutters are essentially gears that are used to
form the teeth. This method of gear cutting is based on the principle that any two gears
will mesh if they are of the same pitch, proper helix angle, and proper tooth depth and
thickness.
Process Characteristics:
By using a gear-shaped corresponding cutter that is rotated (in relation to a blank gear)
produces the gear teeth. The cutters that are rotated are timed with the workpiece. This
process produces internal gears, external gears, and integral gear-pinion arrangements.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
Process schematic
The developing process of gear shaping involves a toothed disk cutter which reciprocates in
axial rotations. The workpiece (or blank gear) rotates on a second shaft (spindle). The
workpiece is correspondent with the cutter and it gradually feeds into the cutter while rotating.
If a two-step process is used, all tooth spaces are partially cut before the finishing.
Set up and equipment
The machine used for gear shaping generally consists of a base, column spindle, and an
arbor. The gear cutter is then mounted on the spindle, and the gear blank is mounted on
the arbor. The cutter reciprocates up and down while the work piece(gear blank) is
gradually fed into the cutter. At the end of each cutting rotation, the spindle is retracted
slightly to discourage anymore cutting into the new cut teeth of the gear.
3.4.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
COMPANY PROFILE
D
Y
N
A
M
A
TIC TECHCNOLOGIES LIMITED THE
BEGINNING:-
Dynamatic technologies limited (D.T.L) was incorporated on march 8, 1973,
Promoted by Mr. J.K.MALHOUTRA & UDAYANT MALHOUTRA
(President, Chairman, and Proprietor).
D.T.L was established with technical collaboration from Dowty Hydraulic
Limited, U.K.
It was then known as DYNAMATIC HYDRAULICS LIMI TED.
In 1984, it indigenized the technology and ended its collaboration with Dowty,
becoming one of the key players in the Hydraulic field in India and worldwide.
Product range covers over 2800 varieties of Hydraulic Gear Pumps and
Hydraulics systems.
Also they diversified application In the Defence & Aerospace sectors and in
Metallurgy.
Main manufacturing plant as well as head office is situated at Dynamatic Park,
Bangalore.
Another state of the art manufacturing facility is being setup at Nagpur,
Maharashtra.
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DYNAMATIC TODAY
Largest producer of Hydraulic gear pumps in Asia and one of the top five in
worldwide.
Dynamatic® is the market leader in the field of hydraulics. Dynamatic® products literally reach every conceivable hydraulic user in India, enjoy very high brand recognition and large the Indian market with a share of70%.
They now stand as a medium scale, precision engineering ISO 9001 certified
Company and they have now already certified ISO 9001:2000 and EMS
14001:2004 certification.
Dynamatic® has once of the most extensive marketing networks for hydraulic
products in India, with 16 branches and scores of distributors and stockiest
spread across the length and breadth of the country.
AGRICULTURALHydraulic Gear Pumps manufactured by Dynamatic® have varied applications including
Agricultural Tractors. Dynamatic® is an original equipment manufacturer for all major
Tractor manufacturers in India including MAHINDRA & MAHINDRA, PUNJAB
TRACTORS, SANE DEUTZ-FAHR, ESCORTS LIMITED, BAJA TEMPO
LIMITED, L&T JOHN DEERE, NEW HOLLAND INDIA Etc.
INDUSTRYThe company enjoys the share of the Industrial Market for Hydraulic Gear Pumps in the
country. Dynamatic® pumps are used Machine tool and various other fluid power
systems. The company's customers include BEML, GODREJ & BOYCE, TELCO,
ASHOK LEYLAND, HINDUSTAN MOTORS, and GREAVES & ETC.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
INFRASTRUCTURE
Keeping in the mind the country's thrust on infrastructure development,
Dynamatic® has specially developed an entire range of high pressure Gear Pumps
having application in various Earth Moving & Material Handling equipment Like
Bulldozers, Excavators, Drill Rigs, etc. Dynamatic' s customers in this segment include
CATERPILLAR INDIA, INGERSOLL RAND, L&T, and Etc. currently; there are
no indigenous manufactures for such Gear Pumps: the Company has developed
breakthrough products for this segment and exports to grow this market rapidly in the
near future.
EXPORTS
Dynamatic® Exports its products to over several countries across the world and
its products are universal acknowledged to be world-class. Dynamatic® products are
used as Original Equipment in USA, UK, Canada, and Germany & South Korea.
Recently they have also bagged the National award for excellence in indigenization
of Defence equipments, awarded by Ministry of Defence.
They have also undertaken a plan of vertical integration through which two Foundry
and Heat treatment facilities have been set up.
Their manufacturing . facilities are very good and incorporated the latest
production technologies. This had enabled then to achieve strategic cost & quality
advantages required to succeed in the global company.
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1.
DYNAMATIC VISION
Their vision is to achieve global leadership through total customer satisfaction. They
constantly strive to improve, expand and innovate themselves to attain the highest
quality standards. Their goal. is to increase product features and improve production
consistency which reducing inefficiencies and lowering cost through the use of
innovative technologies.
DYNAMATIC TECHNOLOGIES is the largest producer of HYDRAULIC PUMPS
in South Asia & One of the top ten worldwide. Their manufacturing facilities are state-
of-the-art, incorporated the latest process technologies. Additionally, they have
diversified into a number of related areas, creating a unique, vertically integrated
manufacturing structures, this has enabled to achieve strategic cast and quality
advantages, required succeeding in the global economy. .
DYNAMATIC HYDRAULICS
A) MOBILE HYDRAULICSThey manufacture a wide range of Hydraulic Gear Pumps, Hydraulic Valves & other
Hydraulic element conforming to SAE, BIS and / or DIN standards. They state-of-the-
art manufacturing plant is very flexible. Hence, they can meet varied customer needs
with a range of over 2800 different Hydraulic Pumps, with displacement of 1.23cc/rev to
150 cc/rev. pumps are produced in both cat iron & aluminium. The applications include
Agricultural Tractors, Constructed Equipments, and Material Handling
Equipments, mining and Drilling Equipments.
B) FLUID POWER SYSTEMSThey provide custom tailored solutions for their customers. Their 'product range from
simple Hydraulic Pumping units to sophisticated Maririe power packs, complex aircraft
ground support systems to turnkey industrial installation. Design-build-install-
maintained, energy designs, saving designs, robotics, built in IT interface & controls.
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DYNAMETAL
A) Aluminium Alloy Casting The Dynamatic Foundry manufacturing high casting made from various aluminium
alloys. They can supply both gravity casting as well as pressure die-casting. Their
activity facilities meet the highest international ecological standard.
B) Heat TreatmentDynametal owns sophisticated Heat Treatment facilities for producing Hydraulic,
Automotive, and Aerospace parts. A wide variety of metals & alloys are processed at
temperature range iron- 70 to + 1000c. Process includes solutionizing, precipitations
hardening (aluminium), carbonitriding, case hardening,through hardening, sub-zero
treatments, stress reliving, spherodized annealing (ferrous).
DYNAMATIC AEROSPACE
Dynamatic Aerospace produces exacting Airframe Structures and precision Aerospace
components. Instituted in 1995, this division is currently headed by Air Cmde, Ravish
malhotra, one of India's two cosmonauts.
Dynamatic Aerospace has successfully executed important projects for Defence
agencies of national importance like DRDO, HAL, Etc. products include the wing and
rear Fuselage of LAKSHY A, India's pilot less target Aircraft, and Ailerons Flaps for
the wings for the HJT-36 intermediate Jet Trainer. This is the first time such
capabilities have been developed in the Indian privates sector, and this division is now
taking up development of major Airframe structures for the Sukhoi 30MKI Fighter-
Bomber.
Dynamatic Aerospace Produce the hydraulic Transmission system for India's T-72
Battle Tanks, Steering Control System, Turret Control System and Brake Actuating
System for Arjun Main Battle Tank.
Dynamatic Aerospace is considered to be one of the most reliable quality vendors to
the DRDO and presented with the Creative Partner Award for the year 1998-99 by
DRDO, ADE and ASIEO. The Aircraft Division of HAL in Bangalore also presented
this division the HAL Best Vendor Award for 2003- 04.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
MAIN SECTIONS OF DYNAMATIC TECHNOLOGY LIMITED:
1) Design.
2) Heat Treatment.
3) Production.
4) Assembly and Testing .
. 5) Quality Control.
6) Maintenance.
7) Research and Development.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
8) Packing & Distribution.
9) Dynamatic Aerospace.
PRODUCTS:
1
)
G
e
a
r
P
u
m
p
s
.
2
)
L
i
f
t
A
c
t
u
a
tors.
3)Hydraulic Valves.
4)Other Engineering products for,
i) Aircraft systems.
ii) Battle tanks
iii)Satellite Launch Vehicles
iv)Marine Applications.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
INTRODUCTION TO MAINTENANCE.
Maintenance is the combination of any actions carried out to retain an item or
restore it to an acceptable condition.
It is not a mere repair activity.
OBJECTIVES OF MAINTENANCE
To maximize availability and reliability of Machinery & Equipment.
To extend useful life of assets by minimizing wear &tear and deterioration.
To ensure safety of personnel using facilities.
Maintenance of any device, equipment, system, product or process, makes it suitable
for the given particular task. This requires periodical testing of the system under
consideration. One of the main purposes of testing is to ensure that the system
conforms to an agreed specification, when operating under stared environment
conditions.
Specification is a detailed description of the required characteristic of the system.
The requirement should be contained in the performance specification section of
manufacturer's sales leaflets and instruction manuals.
Periodical checks carried out during the maintenance schedule will reveal the
shortcomings with reference to the specifications and thereby give way for avoiding
breakdown
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
Specification may include the following
1) Type and family
2) Brief description and intended application
3) Outline drawing showing dimension.
4) Most important electrical characteristics and absolute maximum rate
values of voltage, current and power, including figures, graphs and
characteristic curves.
5) Details of manufacturing inspection (if any).
6) Figures of reliability or failure rate.
Approach to maintenance
Six step procedure as below
1) Collect the evidence
2) Analyze the evidence
3) Locate the fault
4) Identify the real cause
5) Repair the fault
6) Test the system.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
IMPORTANCE OF MAINTENANCE
1) The importance of plant maintenance varies with the plant and its productions.
2) Equipment breaks down leads to an inevitable loss of production. If a piece of
equipment goes out of order in a flow production factory the whole line will
soon come to a halt. Other production lines may also stop unless the initial fault
is cleared. This result is an immediate loss in productivity and diminution of
several thousand rupees per hour of output.
3) An improperly maintained or neglected will sooner or later require expensive
and frequent repairs, facilities (such as transportation facilities),buildings etc.,
wear out and need to be maintained to function properly.
a. Plant maintenance plays a prominent role in production management because
plant break down creates problem such as
o Loss in production time.
o Rescheduling of production.
o Spoilt materials.
o Damages in process materials.
o Failure to cover overheads and need for
overtime.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
2.3.4.5.TYPES OF MAINTENANCE
Maintenance may be classified in to following categories:
1) Break down maintenance.
2) Corrective maintenance.
3) Scheduled maintenance.
4) Planned maintenance.
5) Productive maintenance.
4) Preventive maintenance.
BR EAK DOWN MAINTENANCE
Breakdown maintenance implies that repairs are made after the equipments are out of
order and it can not perform its normal function any longer. After repairing the faults.
Maintenance engineer do not attend the equipment until another failure occurs. Break
down maintenance practice is economical for those (non- critical) equipments whose
down time and repair cost is less this way than other type of maintenance. Break down
generally occurs at in opportunity times. So the disadvantages of break down
maintenance are reduction of output, increased chances of accidents, less safety to
workers and machines, more spoiled material and direct loss of profit. So break down
maintenance practice cannot be employed to the critical equipments and also the
equipments and also the equipment which are regulated by statutory provisions, for
examples cranes, lift, hoists and pressure vessels.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
6.
CORRECTIVE MAINTENANCE
In this type maintenance, a study of failure of equipment in service may
warrant a change in design, Material or working conditions of the equipment
and corrective steps are taken.
SCHEDULED MAINTENANCE
Scheduled maintenance is a stitch-in-time procedure aimed at avoiding
breakdowns. Scheduled maintenance practice incorporates inspection,
lubrication, repairs and over haul of certain equipment, which if neglected
can result in break downs. These inspections, lubrication, servicing etc, of
the equipment are included in predetermined schedule.
PLANNED MAINTENANCE
It is an advance over the scheduled maintenance practice. Planned
maintenance visualizes' the contained in a nature job determines the best
method to be adopted, estimates the time, material and cost involved, assigns
jobs to individuals etc., it provides a system of feed back of information
necessary changes in the original plan.
PREDECTIVE MAINTENANCE
It is comparatively a newer maintenance technique. It makes use of human
sense or other sensitive instruments such as:
Audio gauges.
Vibration analyzer.
Amplitude meter.
In predictive maintenance equipment conditions are measured periodically or
on a continuous basis and this enable maintenance men to take a timely
action as equipment adjustments, repair or over haul. Predictive maintenance
extends the service life of equipment without fear of failure.
Rotary shaving cutters operate at high speeds up to 400 ft. per minute. The feed is fine
and the cutter is restricted to a definite zone contact. The cutter removes fine hair like
shavings from the gear tooth surfaces. Because of the fine cuts, the tool pressure is low
and, therefore, there are fewer tendencies to cold working the gear tooth.
The relationship of the axis of the cutter to the axis of the work is crossed. In other
words, they are set at an angle approximately equal to the difference of their helical
angles, usually in the range of 10° -- 15°. This is primarily to obtain a free cutting action
with a minimum of contact pressure, thus eliminating a burnishing effect.
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
Mechanical Dept, Production Tech,BEC,BGK Page 23
The Churchill Gear Shaver is a Universal Diagonal shaving machine. This means that the machine is
suitable for shaving operations by any of the following methods:-
1. Conventional Shaving
2. Diagonal Shaving
3. Underpass Shaving
4. Crown Shaving
5.Taper Shaving
1. CONVENTIONAL SHAVING - Generally for Gears with face widths wider than 1 1/2". In
this method, although gears are shaved using the "Crossed Axes" principle, there is a zero traverse
Angle. In other words, the table moves to the right and left parallel to the column face of machine. The
work is fed across the cutter at a feed rate of from .005" (0.13 mm.) to .020" (0.50 mm.) per rev. of the
work. The length of total would be equal to, or a little longer than, the face width of the gear. At the
end of each stroke, the table automatically changes direction of traverse and at the same time the
rotation of the cutter is automatically reversed
The knee of the machine is fitted with automatic differential up-feed and the control dogs can
be set to utilize a progressively. Diminishing up-feed. At each reversal of the table, the knee of the
machine is automatically fed upwards, for example, a 6DP Gear could be shaved with as many as 6
passes, with up-feed increments per pass of .0015" .0015" .001" and .0005" plus a free pass without
feed. These figures would apply to a stock removal of .003" on tooth thickness, and, therefore, would
vary according to the work to be produced. At the end of the cycle, the table automatically returns to
the correct backlash position for unloading and loading.
2.DIAGONAL SHAVING - Generally for Gear with face widths of 1 1/2" or less. This method of
shaving differs from Conventional shaving chiefly in the direction in which the work is fed through
and under the cutter. For Diagonal shaving the feed is at an angle with the axis of the gear instead of in
line with that axis. The Angle of feed is adjustable. Traverse angles of approximately 55° are normally
selected for "open." gears. When the cutter is wider than the Gear face or from a chart where the Gear
face is wider than the cutter. It is often possible to improve surface finish by small variations to the
traverse angle setting and this can be quickly and easily undertaken on the Churchill Shavers. Diagonal
shaving generally requires a maximum number of four strokes of the table which, combined with the
shorter length of stroke and Auto up-feed, give a reduced shaving time. Using this method there is
more even wear on the cutter because the point of crossed axis is automatically moved across the cutter
face width.
Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
3) UNDERPASS SHAVING - Basically, this method is diagonal shaving using a 90° traverse
angle whereby an extremely short table stroke is obtained. The work piece starts in backlash
condition, moves into a minimum centre position, through to another backlash condition and then
automatically returns. This method is generally reserved for shaving shoulder gears where it is
necessary to overcome interference problems between cutter and work piece.
When underpass shaving, the table stroke is extremely short, consequently crown shaving from
the table movement is not possible. For this class of work Crowning if required must be
incorporated into the shape of the shaving cutter. Because there is practically no table stroke it
is advisable to use Differential Shaving Cutters for Underpass shaving, i.e. the Serrations are
produced to develop a helix around the cutter instead of creating a series of annular grooves.
4. CROWN SHAVING- The main cause of tooth failure and gear noise is what is known
as "end bearing", that is a concentration of stress at the ends of the tooth, where its strength is
least and the tooth vulnerable to shock failure and the effects of fatigue. End bearings may
result from misalignment in assembly, deflection of shafts or mountings under load, excessive
run out or heat distortion. Crowing the tooth form has proven to be the most effective antidote
for "end bearing" and is applicable to both spur and helical gears.
A Crowned tooth has both its horizontal section and its vertical profile modified. A
pitch line section of a crowned tooth would show the tooth thinner at the ends than at the
centre or at the point where maximum thickness is desired.
5. CROWN SHAVING- To achieve or eliminate taper or to adjust the zero angle and
parallelism of the table, a vertical micro adjuster screw is used to tilt the table in relation to the
knee and cutter spindle axis.
Mechanical Dept, Production Tech,BEC,BGK Page 24
Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
MACHINE DESCRIPTION
Machine column The machine column is of rigid 'C' frame construction onto which the various sub-assemblies are
mounted.
Compartments are provided at the left hand side for the hydraulics, at the right for the coolant pump
unit and change gears, and at the rear for the electrics. The hydraulic oil reservoir is a separate tank
housed within the column below the hydraulic compartment. Coolant oil is contained in the base of
the machine and the coolant clarifier is attached to the right hand side of the column foot.
Knee and Table
The knee and table assembly is carried. on vertical ways on the front of the column and the nut
through which the knee elevating screw operates is fastened onto a facing on the foot of the column.
A motor mounted externally on the left hand side of the knee provides the power for both up-feed and
table traverse motions. The doors on the knee give access to the swivel slide adjustment, the trips for
table traverse and up-feed setting, and also to the table cross feed change gears.
Cutter Head and Cutter Head Drive
The Cutter Head is attached to a facing on the underside of the column head and is driven by a
brake motor through the Cutter Head Drive Unit. Motor and Drive Unit are housed in the column
head. Access to the Cutter Head Drive Change Gears is through the hinged lid on top of the box
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Break down Maintenance Of Cutter Head Of Churchill Universal Gear Shaving Machine
PREVENTIVE MAINTENANCE-G8"MECHANICAL CHECKS AND · FREQUENCY
1 Cutter Head ---3 Monthly
1) Check and record spindle radial run out by applying dial indicator against cutter mounting
diameter and turning spindle by hand. (This necessitates the removal of change gear in cutter
head drive unit).
2) Check and record spindle axial run out by applying dial indicator against spindle face and
turning spindle by hand.
3) Check and record axial run out under load by applying dial indicator to a ball bearing at end
of spindle and when running machine under load.
4) Check and record spindle straightness by applying dial indicator to outboards bearing
diameter of spindle, turning by hand.
5) Check oil seals for leaks. Replace seal MIS 30 if leakage is excessive.
NOTE: -- A. If T.I.R. for checks 1, 2 and 3 exceeds".0002(.005mm)
a) Tighten 6 socket head screws in cover GS.B.4069 which carries the rear race.
b) Remove cover GS.C.4070 and adjust locknut SP.l 050/3 until repeat checks 1
and 2 give 0/".0002 max. (0/005mm)
NOTE: -- B. Check 4 should not exceed ".0005 (.012mm)
NOTE: -- C. If new cutter head is installed, check that length of cutter mounting diameter of
spindle is parallel to the table surface with .0002. (.005mm) this applies only to conventional
machines. With universal type machine, this alignment is corrected if necessary by a slight
adjustment to the taper shaving unit
2. Head & Tailstocks - 3 Monthly then every 6 Months
1) Check and record Tailstock spindle radial run out by applying dial gauge to bore of tooling
location diameter and turning spindle by hand.
2) Check and record spindle axial run out by applying dial gauge to tooling location face and
turning spindle by hand.
NOTE: Check 1. TIR should not exceed .0002. (.005mm)
Check 2. TIR should be .0002. (.005mm) These bearings are matched sets and the setting of
their preload is automatic on tightening lock nut SP.1029/4. Should the T.I.R. for check for 1
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or 2 be excessive, then replace the matched sets of bearings. There is no corrective adjustment.
3) Check oil seals for leaks. Replace if hydraulic leakage is excessive.
3. Knee - All models - 6 monthly
If machine is fitted with taper gib on vertical slides:-
1) Remove gib and check for galling, score mark or wear of scraping marks.
2) Clean, oil and replace gib.
3) Press, gib in until it bottoms; back off slightly using lower locknut, lock gib. If machine is not
fitted with taper gib on vertical slides
4) Remove keep strip and check for galling, score marks or wear of scraping by removing four
holding down bolts.
5) Clean, oil and replace strip.
6) Lock the four holding down bolts.
4. Knee - All Models - Yearly 1) Check for wear between input worm GS.D.3022 and worm wheel GS.D3023. Replace worm
wheel if wear is excessive.
2) Check for wear between elevating screw worm GS.D.3983 and worm wheel GS.D.3021.
Replace worm wheel if wear is excessive.
3) Check for wear between table traverse trip disc worm GS.D.3024 and helical gear GS.D.3025.
Replace helical gear if wear is excessive.
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5. Knee & Table - Yearly
1) Remove table by first removing crowing and taper shaving unit.
2) Check that table feed screw locknut is correctly adjusted after removing swivel bracket
GS.B.4375.
3) Check for excessive backlash between table feed screw and nut. Loosen screws and rotate
backlash adjusting nut, clockwise, until all backlash is removed. Tighten screws.
4) Check bush GS.D.4910 for wear. If play is excessive renew bush.
5) Check trunnions and table for wear and scoring.
6) Clean, oil and replace swivel bracket and guide bracket.
7) Replace crowning unit and table.
8) Check alignment to final chart.
6. Crowning Unit - yearly
Check fit of pin tongue in cam slot. If wear exceed 0".0015 (.0381 mm) grid cam slot parallel
and central and fit pin with an oversize tongue with a maximum of".0003 (.0762 mm)
clearance in cam slot.
7. Couplings - 6 Monthly
1) Check knee, cutter head, coolant and hydraulic pump
coupling keys and keyways for wear.
2) Lubrication - 3 Monthly
3) Check operation of lubrication pump in knee by
disconnecting oil feed lines and observing oil flow
(with knee motor running).
4) Yearly
5) Clean lubrication pump filter.
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APPROCH TO MAINTENANCE OF GEAR
SHAVING CUTTER HEAD
EVIDECE COLLECTED:
Machine is not giving required surface finish, found scratch marks on the gear.
Tolerance = -15 microns, Actual= -14to-16 micron.
Out board bearing support (60) is found broken.
Cutter head assembly is giving abnormal bearing sound. Checked all lubrication point and
found it is ok.
EVIDENCE ANALYSIS:
Machine is not giving require surface finish .
• Checked the run out of cutter, allowed-2.5 microns, actual- out of limit. ..
• Checked tailstock run out, allowed-8 microns, and actual-6 microns
• Checked headstock centre run out, allowed-8 microns, and actual-6 microns
•Checked alignment between headstock and tailstock, allowed-l0 microns, actual -8 microns.
LOCATING THE FAULT Since out board bearing support and check nut are broken, cutter head assembly is giving abnormal
bearing sound and all other geometrical test is ok, problem is with cutter head assembly
REAL CAUSES
Bearings are damaged
Check nut 55 broken
Out board bearing support 60 broken
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FAULT REPAIRING PROCEDURE
Preparations for Dismantling:
Before dismantling we should follow the below procedures
Disconnect the power supply & remove fuse carries from cabinet.
Disconnect all the hydraulic power connections.
Disconnect coolant pipe connections
Arrange the required tools & equipments for dismantling
Arrange the racks or the tray for keeping the machine parts in sequence order for
easy usage
Keep cotton waste for cleaning. Start dismantling procedures.
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HEAD STOCK REMOVING PROCEDURE:-
Roughly clean the machine.
>- Remove the cutter cover by loosening nut (61, 4nos.) & dove pin (64, 2nos.).
Remove broken spindle nut (55). - Remove cutter
Remove coolant connections (33, 34, 35&36).
Remove tail stock hydraulic connections.
Remove limit switch from tail stock.
Remove head & tail stock from the table. '
Remove coolant guard.
Remove the dial indicator which is used for lead setting.
Provide wood support for removing the head.
Loose cutter head mounting nut (3 &4, 4nos. each)
Remove the wooden support one by one & slightly pull down the head to the
hydraulic trolley
Move the head to maintenance department work table.
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ITEM DESCRIPTION NO ITEM DESCRIPTION NO OFF OFF
1 CUTTER HEAD 1 14 1/4" UNC. UNB. 1
CAPHD. SCR.
1 1/2" L
2 TEE BOLT 4 15 GEAR SHAFT 1
3 3/4"UNC. HEX 4 16 ? "x1/4" RECT 1
NUT KEY I?" L.
RND.ENDS
4 3/4" DIA. 4 17 SPACER 1
WASHER.
5 SPIGOT 1 18 TIMEN 'PREC. 2
HOUSING 2' BRG.
19150/19268
6 5/16" DIA. 1 19 HELICAL GEAR 1
DOWEL l3/4"L 23 T
7 SWIVEL GEAR 1 20 LOCKNUT 2
8 5/16" DIA. 1 21 10UNC. UNB. 2
DOWEL I" L. CAPHD.
SCREW I" L.
9 ? " UNC. UNB. 4 22 TIMEN 'PREC. 2
CAPHD. SCR. 2' BRG.
33/4"L 17118/17244
10 SPLINED 1 23 LOCKNUT 2
GEAR SHAFT -
11 SPACER 1 24 10UNC. UNB. 2
CAPHD.
SCREW I" L.
12 TIMEN 'PREC. 2 25 BEAARING 1
2' BRG. HOUSING
12175/12303
13 LOCKNUT 1 26 5/16" UNC. 6
UNB.CAPHD.
SCREW 2 1/4" L.
PART NOS
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27 ? "DIA. 2 43 7 /16"x9/32" 1
DOWEL. 2? " L RECTKEY.
1 1/2"L. RND.
ENDS
28 OIL SIGHT 1 44 LOCKNUT 1
WINDOW
TWCALC4610
29 1/2" B.S.P. UNB. 1 45 10UNC. UNB. 1
PIPE PLUG CAPHD.
SCREW 1 1/4" L.
30 COVER PLATE 1 46 TIMENPREC. 1
'0' BRG.
. 28150/28300
31 GASKET 47 LOCKNUT 1
32 10UNC. UNB. 48 10UNC. UNB. 1
CAPHD. CAPHD.
SCREW 3/4" L. SCREW I" L.
33 COOLANT 49 1/4" B.S.P. UNB. 1
BLOCK PRESSURE
PLUG.:
34 GACO '0' 50
RINGRII0.
35 1/4" UNC. UNB. 4 51 SPACERS 1
CAPHD.
SCREW 3/4" L.
36 FILTON 1 52 LOCKING 1
SWIVEL JOINT SPACER
NO 14833
37 1/2" B.S.P. ? " T 4 53 LOCKING KEY 1
MALE ELBOW
ENOTS Yl13
38 ? "DIA 1 54 10UNC. UNB. 1
NYLON CSK SCREW 1/2"
TUBING 2'-6' L
39 CUTTER 1 55 SPINDLE NUT 1
SPINDLE
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56 COVER PLATE 1 68 END CAP 2
57 GASKET 1 69 SHIM 2
58 10UNC. UNB. 9 70 10UNC. UNB. 8
CAPHD. CAP HD.SCR 1/2"
SCREW?" L. L.
59 1 71 GACOOIL 2
SEAL M1 150206
5/16"
60 OUTBOARD 1 72 TIMENPREC. 2
BEARING '0' BRG.
SUPPORT 19150/19268
61 STUDW.D.S. 4 73 1/8" B.S.P L/O 1
405 - 20 21/4" L ENOTS GREASE
NIPPLE
62 1/2" UNC. HEX. 4 74 INTERMEDIATE 1
NUT GEAR SHAFT
(HARDEN)
63 1/2"DIA STD. 4 75 INTERMEDIATE 1
WASHER GEAR
(HARDEN)
64 LOCATING 2 73 1/8" B.S.P L/O 1
DOWEL ENOTS GREASE
NIPPLE
65 PLAIN BUSH 2 74 INTERMEDIATE 1
BRT P6? " GEAR SHAFT
lID.3/4"L
66 BEARING 1 75 INTERMEDIATE 1
SLEEVE - GEAR
67 TRUARC 1
RETAINER
5100-150
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DISMANTLING:-
Cleaned the whole unit.
Removed the drain plug (49) & take out the oil.J
Removed front bearing cover by losing counter shank screws (7 & 8, 9nos.
each).
Removed rear cover (30) by loosening screws (32, 6 nos.) & gasket (310.
Removed chunk nut (23 & 47) by losing lock screws (24 & 48).
Removed bearing housing (25) from the head by loosing cap head screws (26,
6nos.) & dovel pins (2nos.).
Removed check nut (20 & 44) by loosing locking screws (21 & 45).
Pulled out the spindle (39) & key (40).
Removed the bolts (9, 4nos.) & dovel pins (2nos.) for removing dovel gear
assembly.
Pulled out the spigot housing (5) from the unit.
Pulled out gear shaft (15), key (16), helical gear (19),helical gear (42) & key
(43).
Removed the lock nut 13 after loosing lock screw (14).
Pulled out splined gear shaft (10) from the housing.
Removed end caps (68,2nos.) or cutter cover by removing cap head screw
(70, 8nos.) and seals (71, 2nos.).
Pulled out bearings (72, 2nos.).
Removed the bearings (12, 2nos.) from splinted shaft (10).
Removed the bearings (18 & 22) from gear shaft (15) &
from bearing housing (25).
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Removed the bearing (41) from spindle & bearing (46)
from housing.
LEANING AND INSPECTION
All the parts are cleaned thoroughly by using diesel and after cleaning inspect
the parts to find out damages.
OBSERVATIONS:-
1) Threads of spindle (39) worn out.
2) Cutter locking nut (55) broken.
3) Check nut (47) broken.
4) All the bearings are damaged, found deep mark on the
bearings rollers & inner portion of bearings out race.
5) Check the bevel gears & helical gears. [Found it is ok].
6) Check key suiting [key (40) found some play].
7) Cutter cover (60) is broken.
LIST OF SPARES:-1) OUTBOARD BEARING SUPPORT (60) - 1 NO.
2) TIMKEN PRECISION '0' BEARING 19150/19268
(72) - 2 NO.
3) TIMKEN PRECISION '0' BEARING 18200/18337
(41) -1 NO.
4) TIMKEN PRECISION '0' BEARING 28150/28300
(46) -1 NO.
5) TIMKEN PRECISION '2' BEARING 17118/17244
(22) - 2 NO.
6) TIMKEN PRECISION '2' BEARING 19150/19268
/
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7) TIMKEN PRECISION '2' BEARING 12175/12303 (12) - 2
NO.
8) KEY (40)-1 NO.
9)SPINDLE NUT (55) - 1 NO.
10) LOCK NUT (47) -1 NO.
11)GACO OIL SEAL M1150206/16" (72) - 2 NO.
CORRECTIVE ACTIONS
1) Take the drawing of cover (60) as per sample & give order for a new one.
2) Temporally weld the same cover after making a fixture.
3) Order all bearings & oil seals required.
Preparation for Assembling
Before assembling we should follow the below
procedures,
Reap all threaded holes, remove the chips & clean the holes with
thinner and good quality cotton waste.
Use emery paper & oilstone to remove the rust & small burrs.
Clean the surface with thinner and good quality cotton.
Apply oil in light thickness to the cleaned surface Arrange spare parts
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ASSEMBLING
Inspected bearings & match the check nut with spindle & shaft, found ok.
Thoroughly clean all the related parts & cutter head.
Assembled the outer ring of bearings (22, 18, 46, 41, and 12) to the
housing.
Assembled the spindle bearing inner race.
Inserted the spindle through the housing with key & helical gear (42).
Assembled the gear shaft (15) bearing & insert through the housing with
key & helical gear (19).
Placed the check nut of both spindle & shaft (44&20) respectively for
locking helical gear.
Assembled the bearing housing _ to the head with cap head screws (26,
6nos.).
Assembled the inner race of bearing (46 & 22) to the spindle shaft & gear
shaft.
Placed the check nut of both spindle shaft & gear shaft (47 & 23)
respectively & pre loaded.
Checked radial face run out & axial play of spindle. Correct the run out
with in 0.004mm.
Face run out - 0.002 mm.
Axial play - 0.015 mm.
Assembled the spindle gear shaft into the housing with new bearings. Place
the lock nut and load. Rotate the splined shaft & find the movement ok.
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Assembled the spigot housing to the spindle head.
Checked the bevel gear meshing.
Pushed back the mounting bolts (9).
Rotated the spline shaft manually & find it is ok.
Pasted silicon gel on the face of the cover plate (56).
Placed the cover plate & lock using CSK screws (58, 9nos.).
Pasted silicon gel in the rear side cover plate (30) & lock using CSK screws
to the bearing housing (25).
Assembled bearings (72, 2nos.) to the out board bearing support & placed
the bearing sleeve.
- HEAD STOCK MOUNTING PROCEDURE
1) Taken the head stock to machine bed using a hydraulic trolley.
2) Provided wooden packing & slowly up the head and match with T bolt.
3) Put the mounting nut (3 & 4) and rigidly fix it to the machine.
4) Put the drain plug & fill the oil.
5) Fixed the headstock & tailstock to the table.
6) Fixed the limit switch; given hydraulic connections & coolant connections.
7) Fixed the cutter cover.
8) Fixed the coolant guard.
9) Given all hydraulic & coolant connections dismantled at the time of cutter
removing. Put fuse & give power supply.
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CUTTER MOUNTING AND WORK PIECE ACCURACY
TESTING
SETTING U P - O perati o n A
Mount Cutter
1. Cutter Space r It is necessary to ensure that the centre of face width of the cutter is
coincident with the vertical head. The centre line is 1" (25.4 mm.)
from the shoulder of the arbor.
To arrive at the correct spacer width applies the following
expression:-
SPACER WIDER =1" (25.4 mm.}- 1/2 Cutter Face Width.
Seven standard spacers are supplied with each machine and are as
follows:- 3/16”,1/4”,1/2”,3/4”
2. CutterWhen not in use the cutters should be stored in individual wooden
boxes or placed on a flat wooden board or similar surface.
Care must be taken when handling the cutter to avoid knocking the
teeth. against hard objects. Damage can easily result from such
contact.
Having selected the cutter, first ensure that the machine spindle and
spacer faces, and also the bore and faces of the cutter are thoroughly
clean.
If the cutter has been used before, check also that the serrations are
clean and free form swarf
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Place the cutter spacer and then the cutter onto the spindle. In the manufacture of
Churchill cutters, the plain face is the datum face, and this face should be located
towards the cutter spindle shoulder. The cutter should be a close sliding fit. If there is
any tightness, examine the key for burrs.
Tighten the spindle nut and secure with Locking Pad. Check the cutter datum face for
run out. This should not exceed .0001" per inch of cutter radius. Clean the facing on the
cutter head and mount the outboard bearing housing
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SETTING UP-Operation B
Set Cutter Head Angle
The approximate cutter head setting angle is equal to the helix
angle of the gear minus the helix angle of the cutter.
Example 1
Helica l Gear
Helix Angle of gear =30° RH
Helix Angle of cutter-15° LH
Approximate cutter head setting angle - 300RH 15°LH=15°RH
Example 2
Spur Gear
Helix Angle of gear-O
Helix Angle of cutter = 15° RH
Approximate cutter head setting angle =0-
15°RH=15°LH
Having made this calculation, loosen the four bolts on the underside
of the cutter head flange and rotate the head to the required angle.
This is done by means of the square headed adjusting worm shaft
situated immediately above the cutter head, using the handle
provided in the tool kit.
Clamp the cutter head bolts.
Checked tail stock center run out Allowed-8 microns
Actual- 6 microns
Checked headstock center run out Allowed-8 microns
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Actual- 6 microns
Checked alignment between headstock & tailstock Allowed-l0 microns for 150 mm
Actual- 8microns for 150 mm
WORKING ACCURACY TESTING
Working accuracy tests establishes the capability of the machine as regard to machining
of few test pieces under control machining condition.
Working accuracy test done for the following component and found the machine is
capable the specified tolerance in continuous production .
• Tolerance- 15 microns
• Found actual-14 to 16 microns.
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5.6.
CONCLUSION
A system of Preventive Maintenance tries to minimize the problem of Breakdown
Maintenance, provide them regular inspection and minor repairs there by reducing the
danger of unanticipated break down. The underlying principle of preventive
maintenance is that "Prevention Is Better than Cure".
By applying Preventive Maintenance, Machine Breakdown will be reduced so
availability of the machine will be increased, hence total productivity will be increased
and also decreased the total coast of the production. so that profit will be increase.
Team working is imperative for the success of project implementation as the project
include members of different personal background. Typically there are mechanical,
electrical, electronics engineers, specialist, Consultants in the relevant fields, Trainees
etc.
A common purpose and vision is essential" to achieve the required goal. The final
outcome will depend on the effective utilization and combination of different skills,
Talent and responsibilities.
The Knowledge that we have gained in the institute and industry during our training
helped us to successfully complete our project.
Once again we convey our gratitude to all the staff members of
DYNAMIC TECNOLOGY LTD. who have helped us to complete this project work.
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References:
1. The 2009-2014 World Outlook for Gear Shaper Cutters and Gear Shaving Cutters
for Machine Tools and Metalworking Machines. ICON Group International, Inc.
(September 27, 2008)
2. Nabekura, M. et al., Gear Cutting and Grinding Machines and Precision Cutting Tools
Developed for
3. Gear Manufacturing for Automobile Transmissions, Mitsubishi Heavy Industries
Technical Review Vol. 43 No. 3 (2006) pp. 41-47
4. Katsuma, T. et al., Advanced Dry-Cutting Gear Shaper SE25A and Super Dry II
Coating, Mitsubishi Heavy Industries Technical Review Vol. 42 No. 1 (2005) pp. 46-47
5. Davenport-Hines, Richard Peter Treadwell (1990). Capital, Entrepreneurs and Profits.
Routledge. ISBN 978-0714633862.
6. Floud, Roderick C. (2006) [1976]. The British Machine Tool Industry, 1850–1914.
Cambridge, UK: Cambridge University Press. ISBN 978-
0521025553. OCLC 2089096. LCCN 2006-275684,LCCN 75-046133, ISBN
0521212030.
7. Lloyd-Jones, Roger & Lewis, Myrddin John (2006). Alfred Herbert Ltd. and the British
machine tool industry, 1887–1983. Aldershot, England: Ashgate. ISBN 978-0-7546-
0523-2.OCLC 60393261.
8. Rolt, L.T.C. (1965), A Short History of Machine Tools, Cambridge, Massachusetts, USA:
MIT Press, LCCN 65-12439. Co-edition published as Rolt, L.T.C. (1965), Tools for the
Job: a Short History of Machine Tools, London: B. T. Batsford, LCCN 65-080822.
9. Churchill Machine Tool Co. (1956). The story of The Churchill Machine Tool Co. Ltd.: a
history of precision grinding. Manchester: Churchill Machine Tool Co. Ltd
10. ̂ "Charles Churchill and Son, Charles Henry, Dead". American Machinist (New York: Hill Publishing Co.) 44 (12): 395. 23 March 191
Mechanical Dept, Production Tech,BEC,BGK Page 48
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BIBLIOGRAPHY
1. Jagadish
2.
Mechanical Dept, Production Tech,BEC,BGK Page 49
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