Machining of gears (7 steps make you feel simple)
The forming technique, which utilizes a forming milling cutter that is totally consistent with the shape of the groove to be cut to cut out the tooth shape, such as milling teeth, is one of the gear processing methods; the other is the generating method, which uses the cutting tool and the driven gear. Gear hobbing and gear shaping are two processing methods for cutting out the tooth form by meshing with each other. Allow us to gain a thorough grasp of the gear processing process.
Machining of gears
1. Forging
Hot die forging is still a popular blank forging technique for automobile gear components. Cross wedge rolling technology has been actively advocated in shaft processing in recent years. This method is particularly well suited for producing blanks for intricate stepped shafts. It features excellent accuracy, small subsequent machining allowances, and great production efficiency.
2. Normalizing
The goal of this procedure is to produce the hardness required for further gear cutting as well as to prepare the structure for the final heat treatment in order to effectively decrease heat treatment deformation. The gear steel utilized in most cases is 20CrMnTi. Personnel, equipment, and the environment all have a big impact on normalizing, making it difficult to regulate the cooling rate and uniformity of the workpiece, resulting in a huge dispersion of hardness and an uneven metallographic structure.It has an impact on metal cutting and final heat treatment, causing thermal deformation to be significant and uneven, and the quality of components to be uncontrollable. An isothermal normalization method is utilized to accomplish this. The application of isothermal normalizing has proven to successfully modify the shortcomings of general normalizing, and the product quality is steady and trustworthy.
3. Turning
CNC lathes are used to process gear blanks in order to fulfill the positioning requirements of high-precision gear processing, and mechanical clamping is employed to avoid re-grinding the turning tools. The verticality requirements of the hole and the end face also ensure that the size dispersion of large-scale tooth blank manufacture is kept to a minimum. As a result, the accuracy of the gear blank is increased, and the processing quality of the future gears is guaranteed. Furthermore, the high efficiency of CNC lathe processing minimizes the quantity of equipment required and is cost effective.
4. Rolling and shaping
In the gear processing equipment, standard gear hobbing and gear shaping machines are still commonly utilized. Despite the ease of modification and maintenance, manufacturing efficiency is low. Multiple machines are necessary to produce at the same time if a high capacity is obtained. With the advancement of coating technology, re-coating the hob and plunger after sharpening has become quite simple, and the service life of the coated tool may be greatly increased, typically by more than 90%, thereby reducing the number of tool replacements. And the value of sharpening time is enormous.
5. Tooth shaving
Because of its high efficiency, ease of implementation of the design tooth shape, and tooth direction adjustment needs, radial shaving technology is extensively employed in the manufacturing of large-scale vehicle gears. Since 1995, when the firm obtained the unique radial gear shaving machine from an Italian company after undergoing technical transformation, the technology has matured and the processing quality is steady and dependable.
6. Heat treatment
Automobile gears must be carburized and quenched to maintain their mechanical qualities. Stable and dependable heat treatment equipment is required for goods that are no longer ground after heat treatment. The firm used the German company Leuy's continuous carburizing and quenching production line and got good heat treatment results.
7. Grinding
Its primary purpose is to polish the heat-treated gear inner hole, end face, shaft outer diameter, and other elements in order to increase dimensional accuracy and decrease form and position tolerance.
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