Gear manufacturing in industrial production
Gear manufacturing with machine tools
Gear manufacturing is a central process in metalworking that is mainly used to manufacture gears and similar components. This process is based on the machining of tooth profiles that are required for mechanical power transmission. Generally, gear hobbing machines, gear grinding machines, gear skiving machines, gear shaping machines or other specialised gear cutting machines are used, as well as, increasingly, milling machines or machining centres equipped with the appropriate technological equipment and software tools to ensure high accuracy and repeatability.
Typical components that are manufactured by gear manufacturing: Gears, pinions, spur gears, bevel gears, worm gears, toothed shafts, sprockets, couplings, gear shafts, planetary gears.
How gear manufacturing works
In gear manufacturing, the process usually begins with a blank made of metal. This blank is clamped into the gear cutting machine. The actual gear cutting process is then used. Either a milling tool or a grinding tool is used to cut the teeth of the gear out of the blank. In gear hobbing, the tool rotates along the workpiece and mills the tooth profiles into the material. Gear hobbing works according to the principle of the hobbing motion, in which the tool and the workpiece rotate synchronously in order to precisely shape the teeth of the gear.
There are also other gear cutting processes, such as gear shaping or generating grinding, which are used for special applications. In generating grinding, the surface of the teeth is ground to achieve a high surface quality. This process is often used for gears that are required in high-precision applications in the automotive or aerospace industries, for example.
Gear manufacturing is a process in which factors such as tooth pitch, profile shift and module combinations must be taken into account. These parameters influence the load capacity, service life and efficiency of the finished gear. Due to its high precision and flexibility, gear manufacturing is indispensable in metalworking, especially in industries that require complex and resilient gears.
Machine tools for gear manufacturing
At maschinenauswahl.de you will find four different types of machine tools for gear manufacturing:
Gear hobbing machine
A gear hobbing machine uses a hobbing tool to shape gears by gradually removing material. It is particularly suitable for the production of spur and helical gears and works very efficiently.
Gear skiving machine
A gear skiving machine machines gears by means of a fast, skiving movement of the tool. The rotating tool and workpiece move synchronously, resulting in precise tooth flanks with a high surface quality.
Gear grinding machine
A gear grinding machine machines gears by means of rotary grinding. A grinding wheel shapes the tooth flanks and improves the surface quality while the workpiece and the grinding tool rotate synchronously.
Gear shaping machine
A gear shaping machine machines gears using vertical shaping movements. The tool moves up and down axially, shaping the tooth flanks and cutting teeth into the rotating workpiece.
Each machine has its specific areas of application, depending on the desired result and the required precision.
Leading manufacturers of machine tools for gear manufacturing
In our manufacturers directory, you will find companies that produce gear hobbing machines, gear skiving machines, gear grinding machines and gear shaping machines.
You can find out what is important when selecting the respective machine tool in the section of the same name.
What is gear cutting technology?
Gear technology is a specialist field in mechanical engineering that deals with the design, manufacture and optimisation of gears and transmissions. These gears and transmissions are used to transmit torque and movement in technical applications - they are essential for the function of machines, vehicles and systems.
On the one hand, gearing technology includes the geometric design and calculation of gears. On the other hand, it includes the selection of suitable materials and manufacturing processes to ensure the necessary strength, durability and smooth running. Modern methods such as computer-aided simulation and manufacturing processes such as grinding and milling have significantly advanced gearing technology. The result is high-precision, high-performance gears for demanding industrial applications.
What types of gearing are there?
Each type of gearing aims to transmit the torque in a technical application in the best possible way. In other words, efficiency and performance should be maximised and wear minimised. The most suitable type of gearing depends on the torque, speed and size requirements. Only the basic types of gearing will be briefly outlined here:
- Spur gears are the most common and are divided into spur and helical variants. Spur gears enable direct power transmission, while helical gears offer smoother running and a higher load capacity.
- Bevel gears are used where axles form an angle, such as in vehicle drives.
- Worm gears enable high transmission ratios in compact sizes and offer self-locking, which is particularly advantageous for machine tools.
- Planetary gears consist of several gears in a circular structure, which enables even force distribution and a compact design.
What is internal gearing?
Internal gearing is a tooth structure in which the teeth are arranged on the inside of a hollow cylinder or ring. It enables the transmission of torque within compact designs and is often used in planetary gears where the inner gear meshes with the outer planet gears.