How to Make Gears
Production processes are designed to create added value. In gear manufacturing, the creation of benefit focuses on achieving QCD (costs, volumes, and deadlines). Production of gears involves an interlinkage of various manufacturing processes. These processes may include forging, casting, powder metallurgy, blanking, and extrusion. Various types of gears are available to suit different needs. Examples of gear types include bevel gears, worm gears, spur and helical gears.
Custom made gears are classified depending on the positioning of the shafts. Understanding the differences between gear types is critical in understanding how force is transmitted in different mechanical configurations. The selection process requires one to consider factors such as dimensions, precision grades (AGMA, DIN, or ISO), heat treatment or teeth grinding, torque and efficiency ratios.
As a result of tremendous advances in the manufacture of gears, it is possible to produce gears efficiently and quickly. Currently, a wide variety of machines are available for the production of gears. The gear manufacturing process can be automatic, semi automatic, or manual. As such, machining is the most populate gear production process involving two main methods: shaping or hobbing. Large volumes of gears are manufactured using machine based techniques. Hobbing employs dedicated machines to make gears by relying on vertical or horizontal spindles In this process, a gear blank is fashioned on a rotating hob. Afterwards, the fashioned gear blank is relayed to a hob cutter for teeth completion. Grinding of gears involves the cutting of metal with a multi-point cutter composed of abrasive particles bonded together on a grinding wheel of the desired shape. The majority of present hardened gears are produced using the grinding process. Gear grinding is slow and is only utilized for the manufacture of high quality hardened gears.
Quality manufacture of gears requires a working knowledge of the mechanical properties of materials used in production. It is equally true where production depends on standardized designs. Production requires engineers to understand factors such as rotational directions, drive train speed ratios, the different kinds of gears, their sizes, and strengths. Other factors that affect the production process include ISO and AGMA classifications, teeth forms, teeth thicknesses, and backlashes. Know more about gear cutting.
Accordingly, the gear design process relies on industry level standards to improve the quality and performance of gears. These benchmarks entail the evaluation of a manufacturer's critical production functions and key engineering processes. Reverse engineering gears is one of the most used of benchmarking standards. Reverse engineering entails the computation of design parameters for the specific gear type. Despite gear calculations and parameters being standardized, the task is often complex. Typically, results obtained by reverse engineering are normally accurate. Reverse engineering requires performing repetitive procedures to obtain relevant data. Acquired measurements provide information regarding design deviations, uncertainty in measurements, and wearing of gears in the application environment.