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An Overview Of Gear Manufacturing Processes

September 28, 2021

An Overview Of Gear Manufacturing Processes

Gear manufacturing is considered one of the most complex metal cutting processes. There has been a growing demand for better productivity of the tools and machinery used in the industry. The process dynamics are undergoing a massive change in the last few years, and the solutions being developed are preventative rather than corrective. 


Types of Gear Process Dynamics


Typically, two types of process dynamics are used in gear manufacturing - soft gear process and hard gear process. Both the processes have the same goal to cut the number of operations through which the gear has to pass through to achieve the required dimensions and tooth form elements. 


Soft Gear Process Dynamic

In this process, gear teeth are created by gear hobbing or shaping, which depends on the constraints of the component design. Soft finishing is performed by shaving, grinding, or rolling to achieve the gear quality grade. The quality requirements remain adequate within the desired specifications, even after the deterioration in heat treatment to satisfy the final performance needs.  


Hard Gear Process Dynamic

Under this gear manufacturing process, gears that are shaped, hobbed, warm forged, or rolled after heat treatment undergo final finishing processes. These can include hard finishing, grinding, or honing of the gears. 


Deciding between these two processes depends on several factors. Each has its benefits and limitations. Additionally, the kind of raw materials used in creating gears also significantly impacts the quality of the finished products. The most favoured material used for gear manufacturing is alloy steel, though there are other options available too. 


Finally, the basic purposes of functional gear materials include the following:


  • Consistency and high machinability
  • Good elasticity for effective forge quality consistency
  • Low and stabilized quelling distortion
  • Well-controlled hardenability for consistent and predictable results


Get the Best Gears from Reliable Manufacturers


To explore more about gear manufacturing methods, you can contact True Gear and Spline and talk to our experts. We can help you learn how you can smoothen your production processes and benefit from them.