Gear cutting and gear wheel manufacturing
Gears are one of the most important elements of mechanical gears that ensure movement, transmission and conversion of torque. The durability and reliability of machines and mechanisms directly depends on the quality of gear joints: from clockwork mechanisms to machine tools and industrial gearboxes. The process of their production includes many high—precision stages, united by a common term - gear cutting.
What is gear cutting?
Gear—cutting is a complex of mechanical operations for the formation of teeth on the workpiece of a gear wheel. The main goal is to obtain a profile that will accurately match the specified geometric parameters and ensure proper engagement with the mated wheel.
The most common dental treatment methods include:
- Milling (with disc and worm cutters);
- Chiseling of teeth;
- Stretching during mass production;
- Sheving and sanding for final finishing of the surface.
Each of these methods is selected depending on the accuracy required, the type of gear (spur, bevel, conical, worm gear) and the serial production.
Gear wheel manufacturing technology
The process of manufacturing gears begins with the choice of material — structural or alloy steels, bronze, brass, aluminum alloys are most often used. After the procurement operations (cutting, forging, heat treatment), the workpiece undergoes turning and milling, where the body of the future wheel is formed.
Next, gear—cutting operations are performed - milling or chiseling of teeth, after which the product is subjected to heat treatment (quenching and tempering). This increases the wear resistance and durability of the work surfaces. At the final stage, finishing operations are performed — grinding and polishing, which allow for high accuracy and minimal deviations in the tooth profile.
Equipment and technologies
Modern gear cutting machines are automated systems that provide high accuracy through numerical control (CNC). Such machines allow not only to create complex profiles, but also to optimize the production process, minimizing the human factor.
Control methods are also used in production: measuring tooth parameters, checking runout and alignment, and monitoring surface roughness. The use of coordinate measuring machines and optical systems makes it possible to ensure that the finished product meets international accuracy standards (ISO, DIN, GOST).
The importance of accuracy and quality
Even minimal deviations in geometry