Gear Machining

We have CNC gear shaper machine

Gear hobbing machine, gear milling machine, spline vertical broaching machine, from material forging to precision machining to gear one-stop processing, reflecting the traceability of technology and quality.

Our gear processing equipment can manufacture internal and external gear rings and slewing supports within 2 meters, widely used in transmission, wind power, excavator, tower crane, flow control system and other fields.

Application scenario of gear forging

The forging process is usually required for occasions with high requirements for the strength, wear resistance and life of the gear, and the purposes are as follows:
Heavy gear: engineering gearboxes, mining equipment, wind power gearboxes and other components that withstand high torque and impact loads.
High performance transmission system: heavy truck drive shaft, large axle wheel edge, Marine propulsion system and other areas where the working environment is relatively harsh.

Heat treatment:

The combination of material, forging and heat treatment can better ensure the density and mechanical properties of the material, and wear resistance.

Advantages:

Mechanical properties: strength and toughness are far better than cast or pure machined parts.
Fiber flow lines are distributed along the gear profile to improve fatigue and impact resistance.

Gear blank forming process

1.Hot forging and cold extrusion:metal billet plastic deformation through hot forging or cold forging, forming gear blank and then forming through hobbing, gear shaping and other processes.
Application scenario: Medium and high strength gear (such as automobile transmission, engineering machinery gear).
Features: dense organization, good mechanical properties, strong fatigue resistance, but the cost and mold fees are high.

2.Casting: sand casting, precision casting, etc.
Application scenarios: large, complex shapes or mass-produced gears.
Features: loose, low strength, but low cost.

3.Powder metallurgy:metal powder pressing after sintering.

Application scenario: Small, high-precision gear (such as power tools, home appliances gear).
Features: near net forming, high material utilization rate, but insufficient accuracy, low bearing capacity.

4.Direct machining: direct turning and milling from metal bar material.

Application scenario: Prototype, small batch or high precision gear.
Features: Material waste, general performance, high cost.

Gear tooth shape processing technology

1.hobbing:

The use of hobbing and gear billet mesh motion cutting tooth shape.
Features: High efficiency, accuracy up to IT7-IT8, suitable for small modulus.

2.Gear shaper:

gear shaper cutter up and down reciprocating motion cutting gear shape.
Features: Low efficiency, but the accuracy is equivalent to hobbing.

3. Milling teeth:

cutting tooth by tooth with disk or finger milling cutter.
Features: high flexibility, suitable for large slewing bearing products, but low efficiency.

4. Shaving teeth:

shaving knife and gear to roll, remove a small amount of surplus.
Features: After hobbing process, the accuracy can reach IT6-IT7 level, high efficiency.

5.Gear grinding:

grinding wheel grinding tooth surface, improve accuracy and finish.
Features: The accuracy can reach IT4-IT5 level, used for high-precision gears (such as automotive and aerospace gears), but the cost is high.

6.Gear honing:

Use the honing wheel to improve the roughness of the tooth surface.
Features: Suitable for gear finishing after quenching.

7.broaching teeth:

the inner hole of the broaching tool is formed once.
Features: High efficiency, suitable for small aperture, but the tool cost is high.

Heat treatment process of gear

Gear heat treatment process:

Tempering: improve the overall strength and toughness of the gear (medium carbon steel).
Low carbon steel carburizing: improve surface hardness and wear resistance (such as SAE8620H).

Nitriding:

low temperature treatment, small deformation, suitable for precision gear.
Induction hardening: local hardening of the tooth surface, high efficiency, but low precision.
Post-processing and detection

Gear grinding:

improve the precision level and clearance match.

Testing:

gear measuring center (accuracy), coordinate meter (geometry), hardness test, etc.
Process reference suggestion
Heavy duty, high precision gear forging → gear hobbing → carburizing quenching → gear grinding
Low cost Mass gear Cold extrusion/Powder metallurgy → Shaving (or direct forming)
Large low speed gear casting → gear hobbing → tempering