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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.
The old method of gear cutting is mounting a gear blank in a shaper and using a tool shaped in the profile of the tooth to be cut. This method also works for cutting internal splines. Another is a pinion-shaped cutter that is used in a gear shaper machine. It is basically when a cutter that looks similar to a gear cuts a gear blank.
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.
Gear grinder, which is usually employed as the final machining process when manufacturing a high-precision gear. The primary function of these machines is to remove the remaining few thousandths of an inch of material left by other manufacturing methods (such as gashing or hobbing). Centre Grinding Machine
A rack and pinion has roughly the same purpose as a worm gear with a rack replacing the gear, in that both convert torque to linear force. However the rack and pinion generally provides higher linear speed — since a full turn of the pinion displaces the rack by an amount equal to the pinion's pitch circle whereas a full rotation of the worm screw only displaces the rack by one tooth width.
The pitch surface of an ordinary gear is the shape of a cylinder. The pitch angle of a gear is the angle between the face of the pitch surface and the axis. The most familiar kinds of bevel gears have pitch angles of less than 90 degrees and therefore are cone-shaped. This type of bevel gear is called external because the gear teeth point ...
Hounshell, David A. (1984), From the American System to Mass Production, 1800–1932: The Development of Manufacturing Technology in the United States, Baltimore, Maryland: Johns Hopkins University Press, ISBN 978-0-8018-2975-8, LCCN 83016269, OCLC 1104810110 One of the most detailed histories of the machine tool industry from the late 18th ...
A cycloidal gear is a toothed gear with a cycloidal profile. Such gears are used in mechanical clocks and watches , rather than the involute gear form used for most other gears. Cycloidal gears have advantages over involute gears in such applications in being able to be produced flat (making them easier to polish, and thereby reduce friction ...