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Everything You Need to Know About Gear Manufacturing

June 12, 2018

Gear manufacturing is one of the most complicated metal cutting processes, one in which there is a steady demand for better productivity and accuracy.


Typically, there are two types of process dynamics used in gear manufacturing: soft or hard gear processes.


Both aim to cut the number of machines or operations through which a work gear has to pass to achieve the required specifications in dimensions and quality of tooth form.


  • Soft gear process dynamic - in this option, gear teeth are created by gear hobbing or shaping, which depends on the constraints of the component design. Soft finishing is done by shaving, grinding, or rolling to achieve the gear quality grade. Quality requirements can remain well within the desired specifications, even after the heat treatment deterioration, to meet final performance requirements. 


  • Hard gear process dynamic - with this, gears which are shaped, hobbed, or warm forged or rolled after heat treatment in final finishing operations. These can be hard finishing, grinding, or honing.


The key factor in process dynamics is the overall economy involved. The gear manufacturing processes used to produce the final gear specifications do have limitations. Some of the factors that contribute to errors in manufacturing gear elements include work fixture, cutters, arbors, machined blanks and cutting parameters. The stages of these processes have to decided accordingly. Gears are usually designed to have a finite life service. The most favored materials used for gear manufacturing are alloy steel, which provide the longest life span. To meet quality standards, materials need:


  • Well-controlled hardenability to have consistent and predictable result
  • Least non-metallic inclusions for less machining difficulties
  • Good formability for consistency of forge quality and better forge die life
  • Consistent and high machinability
  • Low and stabilized quenching distortion
  • No grain growth during high temperature carburizing 


In the recent years, significant progress has been made in toughness and fatigue strength using advanced technologies and techniques in manufacturing.


True Gear offers gear manufacturing services that rely on experience and advanced machinery to meet any industrial need. We are committed to top quality, speed and efficiency. Contact us today to learn more or to request a consultation.