Gears are produced in a variety of different ways, so there is no single "process" that can be used to describe the creation of all gears. For beginner, there are many kinds of gears, including traditional "spur" gears, as well as helical gears, herringbone gears and bevel gears. According to their unique requirements, manufacturers must use different processes to efficiently manufacture different gear types.
1) Hobbing. Gear hobbing is a continuous process of cutting, gears, splines and sprockets on a gear hobbing machine. The teeth or splines are gradually cut into the workpiece by a series of cuts made by a cutting tool called a hob, which has evenly spaced teeth to cut the blank. Gear hobbing is productive and provides good accuracy.
2) Forming. Gear shaping is a process used to manufacture gears that cannot be processed by hobbing, such as group gears or internal gears. Among them, the forming tool is very similar to a gear, but with a cutting edge, which rotates at an appropriate speed ratio when cutting into the gear blank.
3) Milling. Gear milling is one of the most well-known gear manufacturing methods and requires the use of a milling machine. It can be used to make almost any type of equipment and is very practical. In traditional gear forming milling, the manufacturer uses a forming tool to penetrate the gear blank to create the backlash required to form the gear. Due to its low accuracy, form milling is somewhat outdated. The latest improvements in CNC modeling and multi-axis machining centers rejuvenate gear milling. The new CNC process uses standard milling cutters and complex CAD and CAM procedures to manufacture high-quality gears. Gear milling can be used to cut all types of gears, including spur gears, helical gears, herringbone gears and bevel gears.
4) Cut diagonally. Bevel gear cutting requires special equipment specially designed for cutting this type of bevel gear. Due to its complex shape, bevel gears are one of the most professional gear types in the manufacturing industry.
1) Gear manufacturing has better structural integrity. Professionally designed and detail-oriented gears tend to have better structural integrity. Those products that have no manufacturing or design defects will last longer over time.
2) Gear manufacturing is more suitable. Most gears are ultimately used in machines that require a perfect or near perfect fit. If the gear teeth are misaligned to any degree, it will affect the efficiency of the machine and may cause gear failure.
3) Low noise in gear manufacturing. Poorly manufactured gears may also produce more noise in the final application.
4) Reduce wear and tear. Even the smallest defects can lead to increased wear; if they are inappropriate or defective, these defects will only grow over time. This will result in a reduction in the life expectancy of your gears, and in some cases, your machine will fail completely.