Gear machining is a highly complex process and requires the use of the right technology to achieve efficient production. Each step of production must be dimensionally accurate.
The gear machining cycle includes:
common turning → gear milling → shaping → cutting → hard turning → gear grinding machining → honing → drilling → hole grinding → welding → measuring
It is crucial to use the appropriate clamping system during the gear machining process. In this text we will present the gear fixing system for each stage of the process.
1. Normal turning
During conventional turning, the gear blank is typically clamped in a vertical or horizontal lathe. Automatic clamping devices, in most cases, do not require an additional stabilizer on the opposite side of the spindle.
2. G ear milling
Gear hobbing is an economical cutting process commonly used to produce external and cylindrical gears. This process is not only popular in the automotive industry, but also in the manufacture of large industrial transmissions, as long as it is not limited by the external shape of the part.
3 . S happening
Shaping is a gear machining process used mainly when milling is not feasible. This method is mainly used for internal gears and some external gears that have complex structures.
4. S having
Shaving is a gear finishing technique in which cutting is done with a cutter that resembles the shape of the gear tooth. This process has gained wide use in industry due to its high efficiency and cost-effectiveness.
5. Quick turn
Hard turning allows the replacement of expensive grinding procedures. For proper functioning, the various components of the system must be properly connected to the machined part. Selection of the appropriate machine tool, accessories and cutting tools is critical in determining the success of the hard turning process.
6.G ear grinding machining
To achieve the level of precision required in modern gear production, hard finishing of tooth flanks is often a necessity. This method is an economical and efficient solution for mass production. On the other hand, grinding offers greater flexibility, especially when adjustable grinding tools are used, similar to individual machining.
7.H alone
Honing is the final finishing process of hard gears, obtained through a not well-defined cutting angle. This process not only offers savings, but also results in smooth surfaces with low noise levels in the machined gears. Honing has a low cutting speed, ranging from 0.5 to 10 m/s, compared to grinding, which eliminates heat-related damage when machining gears.
Furthermore, the internal stresses generated on the surface of the machined tooth have a positive impact on the load capacity of the equipment.
Examples of honing with flanged accessories:
8. D rolling
Drilling is a rotary cutting technique. The axis of the cutting tool and the center of the drilled hole are aligned in the axial direction, and the feed direction is the same as the axial direction of the cutting tool. The spindle that drives the cutting movement must be aligned with the cutting tool, regardless of the direction of the feed movement.
Example of drilling with SG fastening system:
9. Hole Grinding
Hole grinding is a machining process that uses a cutting angle that is not well defined. Compared to other cutting techniques, grinding offers advantages such as high dimensional and shape accuracy, high dimensional accuracy (IT 5-6) and excellent surface accuracy (Rz = 1-3μm) with minimal chatter marks on hard metals.
Example of hole grinding with the SM film clamping system:
10. Capacitive discharge welding
Capacitive discharge welding is a type of resistance welding process. This method involves a rapid increase in current, a brief welding time, and a high welding current. As a result, capacitive discharge welding offers many advantages, including economical and efficient operation, which are particularly relevant due to rising energy costs.
Example of capacitive discharge welding using a welding fixture system:
11. M measurement
Gear testing is comprehensive and must be adapted to different gear shapes. In gear evaluation, key gear parameters are determined by measuring gear length, angles, and specific gear techniques.
Examples of measurements with SP flanged fastening systems:
