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A Quick Guide to Different Material Removal Processes of Gear Cutting

January 13, 2021

A Quick Guide to Different Material Removal Processes of Gear Cutting

Industrial processes and technologies have evolved over time to allow for more precise and accurate material removal. Gear cutting has one of the most difficult processes in the industry which requires precise measurements, employing dedicated tools and machinery to cut into the desired shapes and sizes.


Here are a few different methods and processes of material removal for gears.


CNC Milling

Current CNC technology allows for many machines to operate automatically, cutting and milling different products at a push of a button. Gear cutting is commonly done with these machines. Entering precise measurements into the CNC system will allow it to easily output the desired product after a small amount of time.

The gear blank is positioned either vertically or horizontally. During the process, a milling bit will remove excess material from the metal blank forming the shape of the gear. Sensors will guide the bit around the blank allowing it for further shape the teeth of the gear until the final desired result is achieved.



Widely used for creating spur and helical gears, hobbing is one of the most important generative processes in gear manufacturing. The hob or the cutting tool has serrations that cut the gear blanks either in an axial or in a perpendicular direction. During the process, both the hob and the gear blank in a continuous and timed relationship to obtain the desired specifications of the gear teeth.


Gear Shaping

Gear shaping is another generative process. Gear shaping offers the most flexibility when it comes to manufacturing internal and external parts with interfering contours, and when gear hobbing is not feasible.

During the operation, the cutter’s oscillating movement ensures the cutting operation. The return stroke or the relieving action is important to avoid any damage to the tooth flanks and the cutter. The process continues until the desired teeth configuration is achieved.


Indeed, each removal material process offers unique advantages from speed to accuracy. Nevertheless, talking to the experts at True Gear & Spline Ltd will help you choose the right gear cutting process to achieve the desired output.