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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 .
A hob, the cutter used for hobbing. Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets using 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.
Gear hobbing is a machining process in which gear teeth are progressively generated by a series of cuts with a helical cutting tool. All motions in hobbing are rotary, and the hob and gear blank rotate continuously as in two gears meshing until all teeth are cut.
This process is common among manufacturers of hydraulic and pneumatic cylinders. [1] Compared to honing, skiving and roller burnishing is faster. Skiving can be applied to gear cutting, where internal gears are skived with a rotary cutter (rather than shaped or broached) in a process analogous to the hobbing of external gears. [2]
Broaching is a machining process that uses a toothed tool, called a broach, to remove material. There are two main types of broaching: linear and rotary. In linear broaching, which is the more common process, the broach is run linearly against a surface of the workpiece to produce the cut.
Milling is a cutting process that uses a milling cutter to remove material from the surface of a workpiece. The milling cutter is a rotary cutting tool , often with multiple cutting points. As opposed to drilling , where the tool is advanced along its rotation axis, the cutter in milling is usually moved perpendicular to its axis so that ...
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Gears produced by powder metallurgy often require a sintering step after they are removed from the mold. Cast gears require gear cutting or other machining to shape the teeth to the necessary precision. The most common form of gear cutting is hobbing, but gear shaping, milling, and broaching may be used instead.