Gears are an important part of mechanical equipment, and the precision and quality of their processing directly affect the performance and service life of machines. Gear machining requires several steps, including rough preparation, tooth profile machining, heat treatment and finishing. This article will introduce in detail the different gear processing methods and the machine tools used.
1. Blank preparation
Gear blank preparation includes forging, casting, welding and other processes. Among them, forging is one of the most commonly used processes, in which metal blanks are deformed into gear shapes using dies and presses. Casting involves pouring molten metal into a mold and cooling it to produce a gear blank. Welding is the process of joining two or more metal plates by melting them to form a gear blank.
2. Teeth treatment
Tooth processing is the essential step of gear processing, including gear shaping, gear hobbing, gear shaving and other processes.
gear shaping
Gear shaping is a commonly used tooth processing method, which is carried out using a gear shaping machine. The gear shaping machine cuts metal into the shape of the gear through the movement of the upper and lower tooth shapes. Gear shaping is mainly used to process straight spur and helical gears.
When using a gear shaping machine for processing, it is necessary to select appropriate tools and cutting parameters to ensure processing accuracy and efficiency. Gear shapers are divided into two types: vertical and horizontal. The vertical gear shaper is suitable for processing smaller diameter gears, while the horizontal gear shaper is suitable for processing larger diameter gears.
gear cutting
Gear cutting is a commonly used and efficient method of machining tooth profiles, carried out using a gear cutting machine. The gear hobbing machine cuts metal into the shape of the gear through the relative movement of the rotating tool and the workpiece. Gear cutting is mainly used for processing straight cylindrical and helical gears, and has the advantages of high processing precision and high efficiency.
When using a gear hobbing machine for processing, it is necessary to select appropriate tools and cutting parameters to ensure processing accuracy and efficiency. Gear hobbing machines are divided into vertical, horizontal and universal gear hobbing machines, which are suitable for processing gears of different types and sizes.
shave your teeth
Gear shaving is an advanced method of tooth profile processing which is carried out using a gear shaving machine. The gear shaving machine cuts metal into gear shapes through the relative movement of a pair of cross shafts. Gear shaving has the advantages of high processing precision and good surface quality, but the processing efficiency is low.
When using a gear shaving machine for processing, it is necessary to select appropriate tools and cutting parameters to ensure processing accuracy and efficiency. Gear shaving machines are divided into radial gear shaving machines and axial gear shaving machines, which are suitable for processing gears of different types and sizes.
Gear processing machine tool consultation hotline: 13501282025
3. Heat treatment
Heat treatment is one of the important steps in gear processing. Through processes such as heating, insulation and cooling, it changes the internal structure of the metal and improves its mechanical properties and hardness. Heat treatment is divided into quenching, tempering, carburizing and other processes.
Quenching involves heating the metal to a certain temperature and then rapidly cooling it to change its internal structure and improve its hardness and wear resistance. Quenching involves heating the metal to a certain temperature, keeping it hot for a certain time, and then slowly cooling it to make its internal structure more stable and improve its toughness and impact resistance. Carburizing involves covering the metal surface with a layer of carbon atoms, then heating and preserving it to form a high-hardness carbon film on the surface to improve its wear resistance and wear resistance. fatigue.
4. Finishing
Finishing is the final stage of gear processing, including grinding, sharpening, grinding and other processes. Finishing mainly aims to further improve the precision and surface quality of gears, including reducing dimensional errors, improving roundness, reducing surface roughness, etc.
Grinding is a common finishing method and is done using a grinder. The grinding machine grinds the gear surface with the required precision and roughness through the high-speed rotation of the grinding wheel. Honing is a method of impact grinding of the gear surface using a sharpening head, which can improve the precision and flatness of the gear surface. Grinding is a friction and wear method on the gear surface using abrasives, which can reduce surface roughness and improve surface accuracy.
In short, gear processing requires several steps and processes to obtain high-quality gears. Different processes and methods are suitable for different gear types and processing needs. In actual production, appropriate processes and methods should be selected according to specific circumstances to ensure the quality and efficiency of gears.
Daguang focuses on providing solutions such as precision CNC machining services (3-axis, 4-axis, 5-axis machining), CNC milling, 3D printing and rapid prototyping services.
