Customized rough manufacturing of gears:
Forging: 1. Free forging: used for multiple varieties, single piece small batch production; 2. Die forging: mainly used for mass production
Casting: used for the production of cast iron gear blanks
Tooth blank processing
Customized shaft gear blank machining for gears:
1. Milling two end faces（
2. Drill two center holes（
3. Precision turning of journal, outer circle, cone, and end face
4. Grinding process journal and positioning end face
Customized disc gear processing:
1. Turning the end face, boring the inner hole, and completing rough and fine machining in two steps
2. Turning the end face, boring the inner hole, and completing rough and fine machining in one clamping process
3. Drawing inner holes, turning end faces and outer circles process
Processing splines, keyways, threads, etc
Multiple combination schemes can be flexibly adopted based on production scale, equipment conditions, and accuracy requirements; Select corresponding processing methods according to different accuracy requirements, such as pulling, inserting, turning, grinding, etc.
Customized gear tooth profile rough machining and semi precision machining:
According to the accuracy requirements, cut out the gear groove from the overall blank, sometimes leaving appropriate finishing allowance on the groove side.
Cylindrical gears: forming milling, gear hobbing, gear shaping, etc;
Straight bevel gears: forming milling, precision forging, rough tooth drawing, gear planning, etc
Curved bevel gears: precision forging, specialized rough cutting machine milling teeth, etc
Tooth shape precision machining (before heat treatment)
Cylindrical gears: rolling, inserting, shaving, squeezing
Straight bevel gears: Planer teeth, double disc milling teeth, circular pull farad teeth
Curved bevel gears: milling teeth
Tooth end chamfering and deburring
Shift gear: The tooth end is trimmed to the required shape as required; General gears: remove sharp edges and burrs on both sides of the teeth
Geometric accuracy inspection of gears
Do not require heat treated gears, this process is final inspection, otherwise it is intermediate inspection
heat treatment
According to different materials and requirements, commonly used methods include quenching and tempering, carburizing and quenching, and high-frequency quenching
Precision machining of installation reference surface
Shaft type gears: precision grinding of each installation journal and positioning end face, and trimming of the center hole; Disc gear: precision grinding of inner holes and positioning end faces; This process is often used as a positioning reference for dividing circles or dividing cones
Customized tooth profile machining of gears (after heat treatment):
Select machining methods based on the accuracy requirements, production batch, and size and shape of gears
Grinding teeth: used for cylindrical and bevel gears with high precision requirements, with low production efficiency
Wang Xingchi: used to reduce surface roughness and noise, with high production efficiency, mainly used for mass production
Tooth grinding: used for curved bevel gears, which can reduce surface roughness, reduce noise, and improve contact area
Strong shot peening: improving the bending fatigue strength and contact fatigue strength of gears
Phosphating treatment: To reduce friction between tooth surfaces, the tooth surface should undergo phosphating treatment
Function: Reduce friction coefficient; Preventing surface adhesion under high loads
Clean the tooth surface: remove burrs and dirt from the tooth surface
Inspection of finished gears:
Cylindrical gear: Check its geometric accuracy, contact area, and noise according to the drawing requirements
Bevel gears: Paired on a rolling inspection machine to check the position, size, and shape of the contact area, and to check for noise. Paired gears are marked for easy assembly and use.
