Gear Machining - Quanzhou Weforging Machinery Manufacturing Co., Ltd.

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♦We have CNC gear shaper machine

Gear hobbing machine, gear milling machine, spline vertical broaching machine, from material forging to precision machining to gear one-stop processing, reflecting the traceability of technology and quality.

Our gear processing equipment can manufacture internal and external gear rings and slewing supports within 2 meters, widely used in transmission, wind power, excavator, tower crane, flow control system and other fields.

▼Application scenario of gear forging

◊ The forging process is usually required for occasions with high requirements for the strength,

wear resistance and life of the gear, and the purposes are as follows:
Heavy gear: engineering gearboxes, mining equipment, wind power gearboxes and other components that withstand high torque and impact loads.
High performance transmission system: heavy truck drive shaft, large axle wheel edge, Marine propulsion system and other areas where the working environment is relatively harsh.

Θ Heat treatment:

The combination of material, forging and heat treatment can better ensure the density and mechanical properties of the material, and wear resistance.

Θ Advantages:

Mechanical properties: strength and toughness are far better than cast or pure machined parts.
Fiber flow lines are distributed along the gear profile to improve fatigue and impact resistance.

▼Gear blank forming process

(1) Hot forging and cold extrusion:

metal billet plastic deformation through hot forging or cold forging, forming gear blank and then forming through hobbing, gear shaping and other processes.
Application scenario: Medium and high strength gear (such as automobile transmission, engineering machinery gear).
Features: dense organization, good mechanical properties, strong fatigue resistance, but the cost and mold fees are high.

(2) Casting:

sand casting, precision casting, etc.
Application scenarios: large, complex shapes or mass-produced gears.
Features: loose, low strength, but low cost.

(3) Powder metallurgy: metal powder pressing after sintering.

Application scenario: Small, high-precision gear (such as power tools, home appliances gear).
Features: near net forming, high material utilization rate, but insufficient accuracy, low bearing capacity.

(4) Direct machining: direct turning and milling from metal bar material.

Application scenario: Prototype, small batch or high precision gear.
Features: Material waste, general performance, high cost.

▼Gear tooth shape processing technology

(1) hobbing:

The use of hobbing and gear billet mesh motion cutting tooth shape.
Features: High efficiency, accuracy up to IT7-IT8, suitable for small modulus.

(2) Gear shaper:

gear shaper cutter up and down reciprocating motion cutting gear shape.
Features: Low efficiency, but the accuracy is equivalent to hobbing.

(3) Milling teeth:

cutting tooth by tooth with disk or finger milling cutter.
Features: high flexibility, suitable for large slewing bearing products, but low efficiency.

(4) Shaving teeth:

shaving knife and gear to roll, remove a small amount of surplus.
Features: After hobbing process, the accuracy can reach IT6-IT7 level, high efficiency.

(5) Gear grinding:

grinding wheel grinding tooth surface, improve accuracy and finish.
Features: The accuracy can reach IT4-IT5 level, used for high-precision gears (such as automotive and aerospace gears), but the cost is high.

(6) Gear honing:

Use the honing wheel to improve the roughness of the tooth surface.
Features: Suitable for gear finishing after quenching.

(7) broaching teeth:

the inner hole of the broaching tool is formed once.
Features: High efficiency, suitable for small aperture, but the tool cost is high.

▼Heat treatment process of gear

⊆ Gear heat treatment process:

Tempering: improve the overall strength and toughness of the gear (medium carbon steel).
Low carbon steel carburizing: improve surface hardness and wear resistance (such as SAE8620H).

⊆ Nitriding:

low temperature treatment, small deformation, suitable for precision gear.
Induction hardening: local hardening of the tooth surface, high efficiency, but low precision.
Post-processing and detection

⊆ Gear grinding:

improve the precision level and clearance match.

⊆ Testing:

gear measuring center (accuracy), coordinate meter (geometry), hardness test, etc.
Process reference suggestion
Heavy duty, high precision gear forging → gear hobbing → carburizing quenching → gear grinding
Low cost Mass gear Cold extrusion/Powder metallurgy → Shaving (or direct forming)
Large low speed gear casting → gear hobbing → tempering