Gears have been used by humans for a long time. They are fairly simple machines used to transfer movement and power to the production of work. From bicycles and clocks to automobiles and most industrial machines, almost all machines have gears. In the ever-changing field of gear manufacturing, it is important to choose the most efficient and accurate machining methods and gear tools. Components and production processes and batch sizes determine the choice of tool and gear manufacturing method.
Gear machining is carried out in a soft stage process, where the challenge is usually to obtain tight dimensional tolerances. Careful preparation for the hardening stage provides relatively simple hard part turning operations followed by hard machining of gears. In hard part turning, predictable machining and good surface finish are essential. All of this should be combined with cost-effectiveness.
Gear manufacturing involves many industrial processes. Some of these processes include broaching, gear hobbing and machining. Using the best CNC machining technology, we are able to produce high-quality gears using a variety of industrial gear manufacturing processes. Using CNC machining, gear manufacturing has been able to output a variety of high-quality gears in a fast turnaround time. These gears include helical gears, double helical gears, spur gears, crown gears, worm and worm shafts.
Due to electric vehicles, new gearbox designs, and the need for flexibility and efficiency at the same time, the gear manufacturing process will undergo major changes. The focus will be far away from the common traditional gear machine tools, and replaced by gears/Multi task machining of spline parts will become the norm. Powerful scraping will become the focus because it will replace forming, broaching, spline rolling and gear hobbing to a certain extent.
Gears are usually classified according to the tolerance requirements of the gears after machining operations. The most common standard for cylindrical gear classification is DIN 3962, in which different gear parameters are measured and classified according to levels 1 to 12. Other customer's specific standards are also common, but they all have more or less the same evaluation parameters as the DIN 3962 standard. The gear quality grade of gear manufacturing is usually determined by the component requirements and depends on the gear application field. Other requirements for good gear quality are: high-quality tools, clean contact surfaces, minimal runout of tools and workpieces, stable clamping, accurate and stable machines.