We manufacture an assortment of gears at True Gear and Spline, however, spur gears continue to have a strong foothold in the industrial marketplace. Renowned for their applications in aircraft engines, railway trains, sugar mills, and power stations, these gears also penetrate many of the appliances we take for granted on a daily basis.

 

 

The unique design and manufacturing process involved in the fabrication of these gears are what lend themselves to its prevalence.

 

 

The design features of a spur gear are at the cornerstone to its operational capacity. For example, their straight edged radially projecting teeth, are fundamental to its utility and is created from several machining processes.

 

To garner an appreciation for the capacity of this gear, it is important we outline the machining processes involved for its manufacture:

 

 

Milling

 

The rotary cutter on a CNC milling machine is involved in the process of removing unnecessary portions from the workpiece until the required shape is achieved. The weight of the gear is also optimized during the milling process as it is capable of drilling holes in strategic locations.

 

 

Drilling

 

The drilling process for spur gears allow for the boring of holes through the center of the workpiece, contributing to their characteristic wheel look.

 

 

Broaching

 

Should the gear require internal teeth then broaching is conducted. The broach cutting tool is put to work vertically along the surface of the workpiece, cutting the teeth via a procedure known as linear broaching. This machining process is essential when wanting to produce smooth surface finishes with high dimensional accuracy.

 

 

Hobbing

 

The outer teeth of spur gears are cut through a machining process known as hobbing. In order for this to be successfully carried out the workpiece is continually rotated against the cutter until sufficient depth for the teeth are achieved. Cutting at this stage is done intermittently rather than in one pass as this would cause shifting to occur.

 

It is apparent to see that several important stages occur throughout the fabrication process of a spur gear. This is a concept we are very familiar with here at True Gear and Spline, where we have mastered the craft of manufacturing the highest quality custom spur gear - a statement we can back up through our ISO 9001:2015 certification. Reach out to us for a consultation, our Cambridge Ontario facility is sure to meet your needs!