Chapter 1
1. Introduction
1.1 Fault Finding of Gear Hobbing machine through Root Cause Analysis
One field of research of the working group of students of the Industrial and Manufacturing Engineering Department at University of Engineering and Technology Lahore is the study of Gear Manufacturing Techniques and Methods. Gear Manufacturing techniques are the part of the basic technical study course and students have to perform the techniques practically on the Gear Hobbing machine places in the Machine Workshop of IME Department at UET Lahore.
There are basically two types of Gear Manufacturing methods:
• Gear Generating
• Gear Form-Cutting
Gear generating involves gear cutting through the relative motion of a rotating cutting tool and the…show more content… The cutter may be pinion shaped, a multi-tooth rack-shaped cutter, or a single-point cutting tool.
Gear form-cutting uses formed cutting tools that have the actual shape, or profile, desired in the finished gear. The two primary form-cutting methods are
• Broaching
• Milling.
Broaching is the fastest method of machining gears and is performed using a multi-tooth cutting tool called a broach. Each tooth on the broach is generally higher than the preceding tooth. As a result, the depth of cut increases with each tooth as the broaching operation progresses. Broaching is typically used to produce internal gear teeth. External teeth can be broached using “pot broaching”. In this process a hollow broaching tool, called the pot, is used to cut the gear teeth.
Milling is a basic machining process which uses the relative motion between a rotating, multi-edge cutter and a workpiece to cut individual gear teeth. A variation of the process, called “gashing”, is used to produce large, coarse-pitch gears. Gashing is used on heavy-duty milling machines and involves plunging the rotating cutter into a blank for rapid metal removal.
Gear manufacturing techniques also includes
• Casting and its types
• Sintering and its types
• 3D…show more content… In order to operate Gear Hobbing in practice, it needs to be available and reliable enough, so that it can be used by students and lab attendants. Therefore making sure the availability and improving the reliability of Gear Hobbing is the main goal of this thesis.
There are different approaches to achieve this goal, of which the Root Cause
RCA has been selected because of its cost benefits easy to implement and can be implemented in no time.
The Toyota Production Systems (TPS) a Japanese automotive manufacturing organization, a benchmark for all the manufacturing organizations throughout the worldwide is practicing RCA and RCFA as the part of their Reliability Centered Maintenance. They have implemented RCA and RCFA in their production system as well in their management system.
Analysis has been chosen in context to Toyota Production Systems, that it will be beneficial to implement RCA and RCFA in Industrial & Manufacturing Engineering Department labs so as the part of Reliability Centered Maintenance not only on Gear Hobbing machine but also on the other assets and imported CNC