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Gear manufacturing refers to the making of gears. Gears can be manufactured by a variety of processes, including casting , forging , extrusion , powder metallurgy , and blanking . As a general rule, however, machining is applied to achieve the final dimensions, shape and surface finish in the gear.
Gear cutting is any machining process for creating a gear. The most common gear-cutting processes include hobbing , broaching , milling , grinding , and skiving . Such cutting operations may occur either after or instead of forming processes such as forging , extruding , investment casting , or sand casting .
Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets using a hobbing machine, a specialized milling machine.The teeth or splines of the gear are progressively cut into the material (such as a flat, cylindrical piece of metal or thermoset plastic) by a series of cuts made by a cutting tool called a hob.
Schematic cutaway view of a diffusion hardened metal gear. Diffusion hardening is a process used in manufacturing that increases the hardness of steels.In diffusion hardening, diffusion occurs between a steel with a low carbon content and a carbon-rich environment to increase the carbon content of the steel and ultimately harden the workpiece.
This is an accepted version of this page This is the latest accepted revision, reviewed on 28 January 2025. Manufacturing processes This section does not cite any sources.
The process of gear shaping uses a toothed disk cutter which reciprocates in axial rotations. The workpiece (or blank gear) rotates on a second shaft (spindle). The workpiece is aligned with the cutter and it gradually feeds into the cutter while rotating. If a two-step process is used, all tooth spaces are partially cut before finishing.
Gashing is a machining process used to rough out coarse pitched gears and sprockets. It is commonly used on worm wheels before hobbing, but also used on internal and external spur gears, bevel gears, helical gears, and gear racks. The process is performed on gashers or universal milling machines, especially in the case of worm wheels. [1]
Milling is the process of machining using rotary cutters to remove material [1] by advancing a cutter into a workpiece. This may be done by varying directions [ 2 ] on one or several axes, cutter head speed, and pressure. [ 3 ]
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