Why is gear manufacturing important?

15 Apr.,2024

 

If you want to learn more, please visit our website KSQ Technology.

For more information, please visit KSQ Technology.

Why work with a custom gear manufacturer like Gear Motions? Are not all gears designed and created the same way? If these are questions you have pondered, you have come to the right place.

Custom gear manufacturers not only help optimize the performance of your product, but also your final product costs. These manufacturers don’t sell standard gears that will hopefully produce a desirable result. They customize a gear based on your specifications, with expert staff ready to assist you from design, into prototyping, through production, and into the hands of your customer.

Need more convincing? Here are the top five benefits to working with a custom gear manufacturer.

1) Engineering Services

Custom gear manufacturers have engineers ready to assist you from the beginning of the design process to finished product launch. At Gear Motions, we employ an inside design service team and use Solid Works CAD software to serve our clients. These engineers have over 100 years of combined experience that can help in any stage of the design process, whether creating a new gear, providing reverse engineering, prototyping, or redesigning specific gear components.

2) Availability

There is no need to waste time checking stock or altering a standard gear to fit your needs. Custom gear manufacturers can always provide a solution, saving you time, frustration, and money. Gear Motions has equipment that can accommodate virtually any customer request, including diameters ranging from a fraction of an inch to three feet.

3) Long term cost savings

Working with custom gear manufacturers saves time and money. Less time is wasted searching out gears that have limits on size, performance, and specific operating environments. There is no more guess-work as to which standard gear is best, how long it will last, or how to repair it once problems arise. The engineers that craft your gear know what you want, and how you want it to work. And after creating the initial product, subsequent orders are easily managed.

4) Expertise

Custom gear manufacturers are not new to the field. They have spent years honing their skills to craft expertly made gears. Gear Motions management team has over 100 years of combined gear manufacturing experience. The company was built by forming a network of precision quality gear manufacturers and now works with various markets from oil and gas to aerospace and the military, including many others.

5) Customer Service

Who enjoys calling an automated customer service line? How about calling a real person instead? When working with a custom gear manufacturer, you form a relationship with our sales engineers who know your company and what you need. As an employee-owned company, you immediately talk to an owner when you call Gear Motions, and no one cares more about a happy, satisfied customer than an owner.

Look to the experts in gear manufacturing to help bring your business to the next level. Custom gear manufacturers like Gear Motions are there to help save you time, money, and frustration by getting it right the first time. We’d love to work with you on your custom gear manufacturing projects. Contact us with your project details to get started.

The Importance of Gears in Machinery

Gear Machining Process

Gears have several importance in machinery, and some of them include:

Setting the Rotate Speed

The gear cutting process plays a crucial role in regulating the rotational speed of mechanical systems. A prominent illustration of this function can be observed in the utilization of gears within motor engines. These gears are responsible for finely tuning the rotational velocity of the engine by employing specific gear ratios. Including gears with distinct ratios, such as a 1:2 ratio for an electric motor operating at 1400 rpm, facilitates the modulation of motor revolutions per minute. This enables precise control over the rotational speed.

Transmitting Power

An essential functionality of gears lies in their ability to transmit power between interconnected components without encountering slippage-related issues. A common instance of this capability is evident in the context of lathe machines.

A motor is not directly linked to the primary shaft for maneuvering the chuck within a lathe machine setup. Gears are strategically employed to bridge the gap between the motor and the shaft to ensure adequate power transmission. This facilitates the reliable movement of the chuck.

Changing Torque

Torque is an engine’s rotational force, which is significant in facilitating acceleration. Gear blank play a pivotal role in regulating torque output. The impact of gear diameter on torque production exemplifies this principle.

Larger gear diameters generate higher torque levels, a principle that operates in both directions. The choice of gear blank diameter enables precise adjustments to the torque characteristics of an engine, thereby influencing its acceleration capabilities.

Changing the Power Direction

Gear cutting process facilitates alterations in the direction of power transmission. In addition to their role in regulating speed and torque, gear blank can affect a change in the power’s trajectory. Gear cutting is used in structures such as dam gates and reservoir mechanisms.

A notable example can be observed in operating a door through gears. By employing gears, the manipulation of a door handle can be translated into vertical motion. This enables the controlled upward and downward movement of the door.

What is Gear Machining: An Overview

Gear machining involves the precise creation and gear shaping, which are integral components used in machinery to transmit torque. A gear, characterized by its rotating nature, features gear teeth that interlock with those of another toothed mechanism. This mechanism enables the seamless transfer of mechanical power.

The gear cutting process involves meticulously carving gear teeth onto a spherical blank, forming a perimeter adorned with these essential features. The specialized art of gear cutting encompasses various machining techniques, each designed to produce high-accuracy gears.

The crafting of gears is achieved through various means, including machining, powder metallurgy, casting, and stamping. Among the many available techniques, the most precise and popular ones are gear milling, grinding, broaching, and hobbling methods. These techniques ensure the creation of intricate and well-defined gear profiles.

There are several materials used in the construction of gears, including metals, plastics, and even wood. Advancements in technology have brought forth alternative approaches, wherein metal and plastic gears can be formed through die casting or injection molding. Therefore, manufacturers can look beyond the traditional gear manufacturing process. However, it is imperative to acknowledge that certain instances demand post-production machining to refine the final gear product.

Types of Manufacturing Processes for Gear Processing

Gear Hobbing

Let’s take a look at the various machining processes for gear manufacturing and their unique applications:

Casting

CNC gear hobbing machines are used to produce the teeth of gears. However, casting is a simpler process that is usually used to prepare blanks or cylinders for gears. It is preferred for gear blank because of its ability for mass production and relative simplicity.

However, casting is the most often used production technique in one specific field. That is the manufacture of enormous gears. Gear cutting and other gear hobbing techniques could be more practical in large diameters. Larger gears usually have spur gear construction.

The most popular casting techniques for making gear are shell casting, die casting, sand casting, and permanent mold casting. In other scenarios, other strategies are only partially useful. Nonetheless, those mentioned above are the most common in the manufacturing sector.

Forging

This is an alternative method of production. It is capable of yielding both blank components and pre-fabricated gears. The forging process finds practical usage, mostly in cases involving relatively uncomplicated gear blank designs.

Theoretically, forging is a highly effective technique for fabricating gears intended for heavy-duty applications. This application arises from the necessity of subjecting forged components to a heat treatment process. Thereby impacting the resulting gears with enhanced fatigue-resistant properties. Nonetheless, it is essential to acknowledge that the formidable forces demanded by the forging procedure impose limitations on the dimensions and thinness achievable through this method.

In practice, forging demonstrates optimal efficacy when producing gears ranging from 6 to 10 feet in diameter. Notably, the specific variant of forging utilized, such as precision forging, may dictate whether subsequent machining processes are requisite to achieve the final gear specifications.

Extrusion and Cold-drawing

Machined Metal Gears

This represents an alternative method for gear cutting processes that offers versatility while maintaining simplicity. Extrusion, the technique in question, demonstrates advantageous cost efficiency through reduced tool requirements. However, it is essential to note that this factor may not solely determine the ultimate economic viability.

Extrusion, as the term implies, involves the passage of a heated metal profile through a predefined shape of smaller dimensions. This process yields a solid bar possessing the desired geometric configuration, characterized by a robust and impeccably smooth exterior surface.

An analogous procedure, known as the cold drawing process, resembles extrusion, albeit with particular distinctions. Firstly, while extrusion propels the blank through a die, cold drawing pulls it through. Additionally, a contrasting aspect pertains to temperature manipulation. Unlike extrusion, the cold drawing process abstains from heating the initial billet, consequently enhancing the mechanical properties of the resultant product, albeit at the expense of escalated costs.

Powder Metallurgy

Powder metallurgy is a sophisticated technique that has advanced enormously in recent years. It is now employed in various gear manufacturing processes, including internal gears fabrication. So, how exactly does it work? From the outside, it is pretty straightforward. However, there are numerous complexities involved.

Everything begins with metal powder. The first step is to shape all the powder into the desired shape. After that, the next stage ensures that the entire arrangement is compact, which results in higher mechanical properties. After that, carefully heat the whole arrangement.

It is very efficient, simple, and cost-effective in large quantities. No post-processing will be required, and the product will be ready to use. However, the resulting internal gears have size constraints and cannot withstand excessive load. Furthermore, the initial cost of any powder metallurgy system is relatively costly, making it unsuitable for low-volume gear hobbing. 

Blanking

Gears CNC Grinding

The blanking technique closely resembles extrusion, albeit with some limitations on its three-dimensional capabilities. In this gear manufacturing process, sheet metal is employed with a series of dies to achieve the desired shape. A diverse array of gear types can be fabricated through blanking, emphasizing achieving optimal outcomes when producing spur gears.

The blanking approach to gear manufacturing finds application across many industries, particularly in contexts necessitating lightweight solutions. Noteworthy sectors encompass office equipment, hydraulic systems, minor medical apparatus, and other instances where minimal load prerequisites are pertinent. 

Gear Machining Process

This is a prevalent gear cutting procedure due to its adaptability. While conventional machining methods have historically been employed for gear cutting and production, computer numerical control (CNC) machining has markedly propelled its ubiquity.

Material Selection for Gear Machining

Material Selection for Gear Machining

Gears have a wide range of options regarding the machining materials they can be made from. The earliest gears were crafted from wood, and nowadays, various materials are utilized in gear production across different industries. These materials encompass a spectrum, ranging from robust steel or iron for large-scale industrial gears to lightweight plastic for small gears found in toys. The possibilities for material combinations seem limitless.

However, among the various materials, certain ones stand out as frequently employed in gear cutting processes. These materials are:

  • Cast iron
  • Steel
  • Bronze
  • Plastics

Several distinct factors must be considered when selecting the appropriate material for gears. The specific application of the gear determines the material’s suitability. The chosen material must possess the right balance of tensile strength and endurance for the intended purpose. Another vital consideration is the coefficient of friction, as gears rely on continuous contact. Furthermore, the ease of processing is crucial, as the gear cutting process requires meticulous precision and accuracy. Material may be strong, but it can pose challenges during manufacturing if it’s easier to work with.

The above materials strike a harmonious equilibrium between these essential properties, making them well-suited for their respective applications. This explains their prevalence in the composition of many gears encountered in various settings.

Types of Gears Used in Different Industries

There are several types of gears used in different industries, and some of them include:

Spur Gear

Spur Gear

The spur gear is very common and finds use in power plants, aerospace parts, industrial machines, and more. These gears have straight teeth, which are easy to make and can handle high speeds and heavy loads. However, they can be pretty noisy and better than smooth and quiet operations.

Spur gear can mesh with other gears of the same kind or with internal/external gears. You can see spur gears in various gear setups, like a basic rack and pinion arrangement or a planetary gear system.

Their simplicity makes them easy to create and maintain with precision. Also, spur gear hobbing don’t produce much force in the axial direction, so they work well in gear setups where you want to minimize energy losses.

Worm Gears

Worm Gears

The worm gear system comprises two main parts: a worm wheel and a screw-like gear. It’s commonly used in aerospace, industrial machines, elevators, and car steering.

The worm wheel gear geometry setup doesn’t provide high speed or efficiency. Instead, it has a unique feature needed for self-locking systems. Sometimes, the worm can turn the wheel, but the opposite usually can’t occur due to the angles of the gears. Additionally, worm-wheel gears create a lot of friction and might need ongoing friction to work well.

Helical gears

Helical Gears

Helical gears are almost like spur gears, but their teeth are twisted around a cylinder. This design lets them work well with shafts in different positions. They only mesh correctly with other helical gears having the same twist angle.

Helical gear is used for similar tasks as spur gears. However, the angled teeth help reduce impact and make gear cutting smoother. This leads to less noise, but it does lower efficiency. Helical gears have more energy losses than spur gears and need thrust bearings due to their shape.

From a manufacturing viewpoint, helical gears are more challenging than spur gears. Getting the twist angles right within tight tolerances is tricky. Also, their machining costs and the need for extra parts limit their use to specific tasks.

Bevel Gears

Bevel Gears

Bevel gears differ from regular cylindrical gears. They operate on a slanted surface, which enables altering the transmission’s direction between crossing shafts. While typically used at 90-degree angles, bevel gears can also be applied in different setups. Several common bevel gear types are:

  • Straight bevel gears
  • Spiral bevel gears
  • Miter gears
  • Crown gears
  • Hypoid gears

These types are widely utilized across various applications.

Conclusion

Gear hobbing has transformed as advanced machinery now substitutes traditional hammers. Yet, it remains a precise process, demanding durable gears for harsh conditions. One needs an accurate and efficient gears machining process and well-designed production parts in appropriate quantities to make gears effectively.

AT-Machining Corner Gear Machining

AT-Machining offers you outstanding gears machining services for a wide range of applications. Our machine shop perfectly combines technical expertise and extensive gear manufacturing capabilities to deliver high-quality prototypes and production parts. Our strict quality control system also ensures we efficiently meet your unique demands. Contact us now, and let’s get your project underway.

Why is gear manufacturing important?

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