Why work with GBS Machining Services on gear production?
In addition to gear production, we can assemble, disassemble and maintain gearboxes at GBS.
In some cases, GBS delivers up to 83% faster than OEMs.
GBS produces gear wheels up to and including class 3.
In the absence of information or if you miss a drawing in its entirety, our engineers can reverse engineer it.
By bluing the gears, we can perform quality checks with our MAAG measurement set-ups.
Gear production is a method that has been around for many years, but which nevertheless changes and innovates regularly. The most efficient method to producing gears therefore has to do with the tools and skills of the gear production expert. Checking the production process and pursuing the goal of producting a gear with as few operations as possible is also of great importance.
With gear production in the soft phase, the goal is to stay within the tolerances specified by you as a customer. The better the preparation is, the easier it is to harden after milling the gears. After hardening, it becomes more difficult to machine gears, because, as mentioned, they have become harder.
It is believed that in the future they will produce far fewer gears, because many more electric cars and scooters will be on the market, but this is not the case for GBS Machining Services. The fact is that when milling gears, we mainly focus on offshore, marine and other industrial industries, instead of the automotive or scooter sector.
Yet GBS Machining Services still believes that there is a lot of innovation in gear production methods. We have been working on this for many years and will continue to do so. For example, the normal tools for milling gears can be used in combination, in order to be able to machine multi-task gears. This makes it possible to mill in several ways and several operations are performed simultaneously, which in turn saves time.
Quality of gears
At GBS Machining Services we do gear production from almost any material. Whether you want to supply the material yourself or leave the material of the gears to us, we both agree. If desired, we can also advise you in the choice of material for the gears to be milled. We can mill the standard class for you, but also when you really need precise work, GBS Machining Services is the party for you. We can mill gears to a class 3 accuracy. When milling gears, a class table is used where 12 is low quality and class 1 is the best quality.
What are the influences on the gear quality? And the class? Normally the material, the contact surface and the accuracy have to do with this. This requires a good gear production machine and a skilled operator who knows what to do with the gear in order to ultimately get the milling quality to an exceptionally high level.
Gear production applications
Whith the production of gears, the gear profile must be taken into account. In other words, the size and shape of the teeth should correspond to the type of tool used to mill the gears. If the tool is selected incorrectly, the chance is considerable that the gears are milled too far, killing the gear. Or on the other hand, that too little is milled away, and it takes up an unnecessary amount of time. What should you consider when choosing the tool when you decide to mill gears? Think of the module size, the profile of the gears, and the pressure angle. The top and base diameter are also important. If necessary, GBS Machining Services can assist you in taking care of head and foot corrections. In addition to the top and the base, the helix angle and link type are also important. With a good gear drawing, all these factors will be mentioned.
How gear production happens
Some people want to venture into gear production themselves. You can, and it makes sense, since gears are very often used in the transmission of forces.
For example, you can start with gear production from different materials, such as from metal, plastic or wood. At GBS Machining Services we mainly mill gears from metals. For example, we can propose to do the following. Milling gears with a milling machine. Depending on the quality of the gears, we use a milling machine or a grinding machine from Niles. By means of a Cad / Cam drawing we can manufacture the sprocket in the most economically attractive way for you. If you do not have a Cad / Cam drawing to supply, we can also reverse engineer the gears for the gear milling. Our engineering department will ensure that you get the drawing back in your possession. This is useful in case you need to mill the gear again in the future.
The tool, so the grinding stone or milling cutter that we use, ensures that the teeth are applied. When producing gears for the first time, it is more convenient to use a simple shape and not too many complicated shapes. Mill straight teeth for this. In a gear system as in a planetary system, gears have different sizes. It is important that the module is unchanged, so that these gears simply fit together. This ensures that you do not focus on milling gears for nothing.
gear production: take this into account
If you are getting started with gear production yourself, the following tips will help you with this.
Precision is important in gear production and machining, and since gears are moving parts, this is even more important in gearing. And that is where the production tool comes in. The cutters you use must be of top quality and sharp enough to see, otherwise there may be an error in the accuracy of the gears.
GBS Machining Services is known for coming up with ingenious solutions when faced with challenges, so that we can still do the gear production for you. After all, it is not for nothing that we have Thinking In Possibilities as our slogan. This has made us a competitive party for many years, which saves you a lot of money at the bottom of the line. Our company consists of 99% technicians. From the moment you submit an application, to our logistics employee; everyone has technical insight to a greater or lesser extent and uses this to benefit you. So if you want to have your gears milled, consider GBS Machining Services!
The process of gear production
The round workpiece is mounted axially, perpendicular to the axis of the cutting tool. The tool is moved along the axis of the workpiece and mills out the tooth space. The workpiece is then rotated a distance of one tooth space and the production is repeated. The gears are milled gradually until teeth are milled around the entire gear. To mill bevel teeth on the gears, the cutter makes an angle while cutting, the workpiece is slowly rotated as the tool is moved along the axis of the workpiece.
Gear transmission is an essential part of rotary machinery, where the teeth mesh with another toothed part to transmit torque. How are gears made? Unlike casting or forging, CNC gear production can be used to achieve the final shapes, dimensions and surface finish of a gear. Here we introduce and compare two gear manufacturing methods: gear milling vs gear milling, what are the differences between them?
What is gear production?
Gear production is a common CNC milling machining and gear cutting process for making a gear. It can be used after or instead of milling processes such as casting, forging and extrusion. Gears are usually made of metal, plastic and wood. Many metal and plastic gears made by injection molding, injection molding, or additive manufacturing may not require cutting. For coarse-pitch gears, generative gear milling technology can improve efficiency, increase machine pitch capacity, reduce production costs and reduce machining times.
Which cutter is used in gear production
The gear can be produced on a milling machine or grinding mill by using gear cutter and indexing head or rotary table, the amount of gear cutter is determined by the number of teeth of the gear required. Different types of cutters can be used to make gears, for example the rack former, with six to twelve teeth, straight and movable in a direction tangent to the gear. For the new circular cut, the cutter must return to the starting position.
How can I distinguish types of gear production
1. How the gear production works
When producing a gear, a single tooth pitch or gap between gear teeth is created by a rotary cutter with multiple cutting edges at the same time, the diameter of the generated teeth is similar to that of the cutter. When hollowing out gears, the gear teeth are gradually produced. The hob therefore cuts several openings at the same time.
A shaping mill is used in gear production, when each tooth space is cut, the mill returns to the starting point and the gears are indexed for the next cutting process; the cutter uses a spiral cutter head, and the workpiece both rotate constantly when the hob is fed across the width of the blank.
3. The number of teeth to be cut at one time
Each cutter in gear production is designed to cut a series of tooth numbers, while in gear hollowing out, both the hob and the blank gear rotate continuously, just like two gears that mesh together until all teeth are cut.
4. Price of tools
In general, the cutting tool for gear production is cheaper than a gear milling cutter, but the productivity of gear cutting can be higher.
Gear production is more commonly used for high production runs, and gear milling is a low production process.
- Gear production often requires deburring
- Gear production is often used when other generation processes are not available.
Gear production at GBS Machining Services
Up to 2,000mm
Up to 4,500kg
Up to 4,500mm
Amount of teeth
0.5 - 100
Radial and axial runout