Choosing The Right Gear Cutting Process
There are many steps involved in the gear manufacturing process, but gear cutting is one of the most important. When hiring someone to perform gear cutting, it's important to select a professional who uses all relevant gear-cutting technologies, including broaching, chamfering, shaping and gear hobbing. Which process you should use is based on the type of gear you need to produce and the characteristics you want to gear to have.
Broaching is a technique that is effective for large gears and splines. This type of tool can be customized based on the required shape of the final product. In some cases, broaching is needed when an object needs an odd shape. However, gears are more likely to need a uniform shape. With some involute gears, broaching has replaced hobbing.
Shaping is a traditional method of cutting gears. A blank gear is rotated alongside an incomplete gear that is a template. This process can be very effective at forming internal and external gears. There are certain types of gears, such as helical gears, that are best produced through this process.
Gear hobbing is the most common method used for cutting gears. It uses a piece of equipment known as a hobbing machine. The hob cuts grooves into a blank gear through an automated process. It offers flexibility regarding the working angle of different types of gears. As the blank gear rotates, it's smoothed cleanly and methodically. Hobbing is one of the fastest ways to cut a gear. With the right expertise, hobbing can be performed with precision. Hobbing is very flexible and can have many applications. However, it is not a process that you can use to create internal gears, so you may need to use more than one process to cut all of your gears.
Gear Chamfering and Deburring
The chamfering and deburring of gears is often a neglected part of the process. Chamfering gears will reduce the risk that they will break. Too much carburizing along the tooth edge can cause breakage when the gear is running. When burrs are not removed, they can chip off during the running cycle and cause damage to other gears and other parts of the machinery. The tool will have a short lifespan and will develop sharp burrs, which can lead to injuries. But with the right gear cutting processes, you'll be able to create gears for any application.