The digital era to lead the machine tool comprehensive digital change, in recent decades, machining process has undergone a sea change, thanks to the equipment comprehensive digital coverage.
Gear processing equipment is also a comprehensive update of the digital, the process has also undergone greater changes, some of the more difficult products for tooth processing is relatively easy up, the process has become relatively rich, incomplete statistics, today’s manufacturing process for processing gears no less than 20 kinds of manufacturing process methods, summarised as follows:
| 1. Gear milling (distinguishing between standard milling cutters and profile milling cutters) | 2. Gear hobbing (forming hob hobbing, mainly CNC hobbing machine and five-axis turning and milling machine to complete) |
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| 3. Gear insertion processing (CNC insertion machine and shaped gear cutter processing) | 4. Shaving (shaving machine and shaving cutter processing) |
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| 5. Gear turning (5-axis machining with specialised turning tools) | 6. Gear grinding (CNC gear grinding machine and profile wheel grinding) |
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| 7. Honing (Honing machine tools and honing tools honing – ultra-precision machining) | 8. Wire-cut processing (wire-cut processing of spur gears) |
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| 9. Powder alloy manufacturing (mould pressing – heating and sintering – heat treatment – post-treatment) | 10. Waterjet machining (CNC waterjet seven spur gears) |
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| 11. Laser cutting (CNC laser cutting machine for spur gears) | 12. Broaching (CNC broaching and internal spline machining) |
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| 13. Tooth planing (planer and shaping cutter tooth planing) | 14. Electrochemical processing (electrical discharge and chemical electrolytic processing) |
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| 15. Stamping (CNC press mould stamping of spur gears) | 16. Spinning process (belongs to the type of cold extrusion, there are hot spinning cold spinning) |
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| 17. Combs (comb machines and comb processing) | 18. File the teeth (CNC rolling machine and rolling knife processing) is suitable for high-volume processing |
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| 19. Casting Technology (Silica Sol Precision Casting and Turned Sand Casting, etc.) | |
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Gear manufacturing process :
Gear machining process introduction
Gear machining process can be roughly divided into the following stages:
| 1. tooth blank processing | After heat treatment of the blank into the machining, this stage is mainly for the next stage of processing tooth shape to make preparations, mainly machining out the benchmark, so that the accuracy of the tooth bore and end face basically meet the specified technical requirements. |
| 2. Tooth shape processing | This stage is mainly on the shape of the gear for finishing, after this stage can be processed to fully meet the requirements of the drawing of the gear to, must be processed in this stage to meet the tooth shape of the final finishing required by the tooth shape accuracy. |
| 3. Heat treatment | If you don’t need quenching, gear manufacturing can be completed by tooth shape processing, the need to quench the gear is mainly to make the tooth surface to achieve the required hardness. |
| 4. Tooth shape finishing | After the quenching of the gear usually need to carry out finishing processing, in order to correct the gear after quenching caused by the deformation of the tooth shape, further improve the accuracy of the tooth shape and reduce the surface roughness, so as to achieve the final accuracy requirements. |
| 5. Tooth end processing (post-treatment) | Gear tooth end processing has chamfering, chamfering, chamfering, deburring and other processing, chamfering, chamfering gear, along the axial sliding easy to enter into the mesh; chamfering can be removed from the tooth end of the sharp edges, to prevent the gear transmission of the sharp edges of the easy to collapse. |
There are various forms of tooth shapes, among which the involute tooth shape is the most common. There are two main types of machining methods commonly used for involute tooth forms, namely, the forming method and the spreading method.
| 1 Gear milling |  |
The use of disc-shaped modulus milling cutter or finger milling cutter milling belongs to the shaping method of processing, milling cutter teeth cross-section shape and gear tooth shape corresponds to. This method of processing efficiency and processing accuracy are low, only for single piece of small batch production. |
| 2 Forming grinding |  |
Also belongs to the forming method of processing, because the grinding wheel is not easy to dress, use less. |
| 3 Hobbing |  |
Gear hobbing belongs to the spreading method of machining, and its working principle is equivalent to the meshing of a pair of helical gears. The prototype of the gear hob is a helical gear with a large helix angle, because the number of teeth is very small (usually the number of teeth z = 1), the teeth are very long, around the shaft to form a worm with a small helical angle of lift, and then after the grooving and shovelling of the teeth, it will become a hob with cutting edges and back angles. |
| 4 Shaving |  |
In mass production shaving is a common finishing method for unhardened teeth. The principle of operation is to use the shaving knife and the processed gear for free mesh movement, with the help of the relative slip between the two, from the tooth surface shaved down very fine chips to improve the accuracy of the tooth surface. Shaving can also form a drum-shaped teeth, to improve the position of the contact area of the tooth surface. |
| 5 Shaping |  |
Gear insertion is in addition to hobbing a commonly used method of using the spread into the tooth cutting process. Gear insertion, shaping knife and the workpiece is equivalent to a pair of cylindrical gear meshing. Reciprocating motion of the shaping knife is the main movement of gear insertion, while the shaping knife and the workpiece according to a certain proportion of the circumferential motion is the feed movement of the insertion. |
| 6 Spreading grinding |  |
Spreading method grinding cutting motion is similar to hobbing, is a tooth finishing method, especially for hardened gears, is often the only finishing method. Spreading into the method of grinding can be used worm grinding wheel grinding, can also be used conical grinding wheel or disc grinding wheel grinding. |
| 7 Honing |  |
Honing principle is similar to shaving, honing wheel and workpiece is similar to a pair of helical gears without backlash meshing, the use of meshing at the relative sliding, and in the tooth surface between the application of a certain pressure to honing. |
| 8 EDM wire cutting |  |
EDM wire cutting is referred to as wire cutting. It is in the electric spark piercing, forming processing on the basis of the development. It not only makes the application of electric discharge machining has been developed, and some aspects have replaced the electric discharge piercing, forming processing. |
Gear machining is an extremely complex process that can only be made possible through the application of the right technology, and each part of the production process must also be extremely dimensionally accurate.
If you have a need for a gear processing machine, please feel free to contact us. We have rich experience in manufacturing and application, and can provide you with professional technical support.
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