Analysis of Process Parameters in

Hobbing using Optimization Technique

Presented By
Miss. Swapna V. Shewale
Guided By
Prof. Shubham R. Suryawanshi

METs Institute of Engineering, Nashik.

Introduction
Hobbing is a continuous gear generation process
Gear hobbing is one of the major manufacturing
processes in the industry.

Fig. 1 Gear hobbing process [7]

Literature Review
SR.
No.

Title

Author

1.

Estimating hobbing
times

Robert Endoy

2.

An Innovative Way
of Designing Gear
Hobbing Processes

F. Klocke, C.
Gorgels, R.
Schalaster

A Review of New
Strategies for Gear
Production

G. Hyatt,
Markus P.,
Chaphalkar, O.
Kleinhenz, M.
Mori,

3.

Year
1989

2011

2014

Remark
Calculated cycle time & it
reduces with increase in hob
start
Demonstrated the ability to
attain through simulation
cheaper,
faster
process
development
for
gear
hobbing
Compared two techniques
and their quality and
production times and also
discussed the additional
benefits of two methods
invomilling and five axis
machining using gearmill.

Sr.
No.

Title

Author

4.

Experimental investigation E. Aslan,

of cutting tool
performance in high speed
cutting of hardened X210
Cr12 cold-work tool steel
(62 HRC)

2005

Used different tool

material.

5.

High Performance Gear

Hobbing with powdermetallurgical High-SpeedSteel,

2012

Used PM HSS &

Carbide tool &
observed development
of dry cutting is
increasing regarding
rising cutting
parameters and
productivity

Karpuschewski,
Hans-Joachim
Knoche, Martin
Hipke, M.
Beutner

Year

Remark

PROBLEM STATEMENT

In automobile industries the emand for gears is increasing day

by day.
To satisfy increasing demand needs to improve the
productivity.

OBJECTIVES
To find the optimum Process Parameters in gear
hobbing.
To improve the productivity.
To reduce the cycle time.
To carry out experimentation using different cutter
materials on gear hobbing machine.

Experimental Set Up

Machine Specification

Vertical hobbing Machine

Hob Cutters-40 mm, 48 mm & 60 mm
Surface Roughness Tester-To Find the Surface Roughness

Vertical Hobbing Machine

Make
Controller
Dia. Of work table
Hob Revolutions
RPM
Max. module to be
hobbed

COOPER
Fanuc
250 mm
80-500
6

Taguchi Method

Workpiece Material

Table 1 : Chemical composition of workpiece

Grade

C (%)

Mn (%)

Si (%)

P (%)

S (%)

EN8

0.35-0.44%

0.60-1.00%

0.10-0.35%

0.05 Max

0.05 Max

Selected levels for parameters

Table 2 : Levels of parameters
parameters

Level 1

Level 2

Level 3

Hob Speed (RPM)

160

180

200

Feed Rate (mm/rev)

1.25

1.6

2.0

Hob Diameter (mm)

40

48

60

Hob Material

M2

HSS

D2

Conclusion

Optimization is the most effective tool to find out the optimal

parameters to achieve the required result.
To optimize process parameters such as hob speed, feed, hob
Material etc., Taguchi method combined with suitable in order
to take care of the possible correlations between the response
variables.
The different levels are finalized using DOE technique as
entitled in table II for comparative analysis, the cutter
materials are selected on the properties of material and
literature carried out.

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