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The Different Stages of Gear Manufacturing and How They Work

January 30, 2018

The Different Stages of Gear Manufacturing and How They Work

Gear manufacturing is the process of creating or fabricating gears according to need or specification. The entire process starts with metal cutting, fabricating it to a specific size. The initial gear will have no teeth – this is called a blank gear. Once a blank gear is produced it will undergo several steps before reaching its finished product. Fabrication of gears involves three key processes, vital operations that will determine the quality of the gear.

This is how gears are typically made, and at True Gear we are happy to answer any questions or provide expert advice for any project. We can help your enterprise through the process, providing expertise, insight and advice based on years of qualification.


The Three Main Stages of Gear Manufacturing


Gear Formation: Once the blank is manufactured and ready, it will undergo gear formation. A precise cutting tool is used to outline and cut the teeth of the gear. The cutting tool is shaped according to the space that is needed between the gear’s teeth.


Form Milling: The second stage of the process is called form milling. In this process, a form cutter travels on the axis of the blank in order to cut the proper depth and length of the tooth. Once the tooth is cut, the gear is rotated on its axis to allow the form cutter to cut the next tooth. The process is repeated until all the teeth of the gear are cut.


Gear Broaching: This stage is done if internal splines are to be created. This process uses a rapid succession of form milling because it is done internally. It requires extreme dimensional accuracy which can make it a very expensive process.


Gear fabrication is fascinating – so if you’d like to learn more or obtain a quote, just call or visit True Gear Today!