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Gear manufacturing machine illustration showing the headstock. Headstock center true-up is checked as part of a troubleshooting inspection.
Gear manufacturing machine illustration showing the headstock. Headstock center true-up is checked as part of a troubleshooting inspection.

Gears: Cylindrical Gear Manufacturing Troubleshooting

Gears: Cylindrical Gear Manufacturing Troubleshooting is a highly visual course designed for an advanced learner who has prior knowledge of gear terminology, gear manufacturing, and gear chart interpretation. Ready to take the next step? Explore the course details and see everything we’ve packed into this program!

Learning Hours: 2.5

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Course Description

Gears: Cylindrical Gear Manufacturing Troubleshooting is a highly visual course designed for an advanced learner who has prior knowledge of gear terminology, gear manufacturing, and gear chart interpretation. In this course, learners are introduced to the common manufacturing errors that manifest themselves on gear charts. The course then provides an understanding of the potential root causes of the errors, followed by a discussion on the tips and techniques that can be used to correct the errors.

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Who will benefit from this Cylindrical Gear Manufacturing Troubleshooting course?

Gear Manufacturing Engineers, Gear Cutting & Gear Grinding Machinists, Quality Inspectors, and any learner who must be familiar with the common gear manufacturing errors and how to correct them.

Course Classification

This manufacturing course by THORS eLearning Solutions covers application of the included topics.

*THORS uses the Bloom’s Taxonomy Methodology for our course development.

Certificate Awarded for Gears: Cylindrical Gear Manufacturing Troubleshooting

Example of certificate awarded upon successful completion of the course.

*upon successful completion

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Learning Objectives

  1. Identify the most common errors seen on gear charts that occur during gear manufacturing.
  2. Distinguish between and understand the potential root causes for the most common manufacturing errors.
  3. Apply the proper techniques to correct the most common manufacturing errors.

Shaft pinion true-up being performed, one technique used to correct and prevent gear manufacturing errors.

Gears: Cylindrical Gear Manufacturing Troubleshooting

Table of Contents

  1. Introduction to Cylindrical Manufacturing Troubleshooting
  2. Identifying Common Manufacturing Errors
    1. Helix Wobble
      1. Chart Characteristics
      2. Part Performance
    2. Helix Off-Angle
      1. Chart Characteristics
      2. Part Performance
    3. Helix Taper
      1. Chart Characteristics
      2. Part Performance
    4. Combination of Helix Errors
      1. Chart Characteristics
      2. Part Performance
    5. Profile Wobble
      1. Chart Characteristics
      2. Part Performance
    6. Other Errors
      1. Profile Off-Slope
      2. Profile Taper
      3. Base Pitch Error
      4. Cumulative Pitch Error
      5. Tooth Thickness Error
  3. Root Causes of Errors
    1. Incorrect Headstock Centering
    2. Incorrect Tailstock Centering
    3. Improper Machine Alignment
    4. Inconsistent Part True-Up
    5. Tooling Errors
  4. Tips and Techniques to Correct Errors
    1. Headstock Check
    2. Orbit Check
    3. Machine Alignment
    4. Part Alignment
      1. True-Up for a Bored Gear
      2. True-Up for a Shaft Pinion

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