Gear machining is a precise and complex manufacturing process involving multiple steps, often using a variety of cutting tools. The following are common cutting tools used in gear machining processes:
Initial shape
Milling: Using a milling cutter to create a preliminary shape on a blank, removing excess material and forming a shape that is close to the final shape.
Tooth processing
Gear shaping: Use a gear shaping cutter to process the preliminary tooth profile of the gear. Gear shaping is an efficient gear shaping method for both spur and helical gears.
Gear hobbing: In the gear hobbing process, a hobbing cutter or roller is used to press out the tooth shape of the gear. The process is suitable for high-volume production and enables gears to be manufactured quickly and accurately.
Plunge grinding or gear grinding: For applications requiring high precision, a gear grinder may be used for finish grinding after gear shaping or hobbing to achieve greater accuracy and surface finish.
Gear finishing
Grinding: Precision grinding of gears using gear grinders and grinding wheels to further improve the accuracy and surface quality of the gears.
Honing: Honing is a high-precision processing method that uses a honing machine and a honing stone for final processing of the gear to improve the contact accuracy and life of the tooth surface.
Gear modification
Tooth tip dressing and tooth root dressing: In special applications, the tooth tip or tooth root of the gear may need to be modified and machined using special cutting tools to meet specific functional requirements.
Hole processing and other special processing
Drilling and Boring: For gears that require a fixed shaft or other component, holes are machined.
Threading: If threads are required on the gear, the threading is done using a tapping tool or a thread milling cutter.