The Most Established Gear Grinding Techniques

In mass production of small gears to large sized gears, gear finishing technologies are utilized to reduce vibrations and noise during automotive transmissions or to improve the efficiency of gears in power generators. Among the techniques used, gear grinding is commonly chosen along with hobbing and honing.

 

Gear grinding is the finishing process in shaping the teeth of gear, which are usually hardened to provide high accuracy and a fine finish.

 

The gear is machined with a grinding allowance prior to heat treatment. After being heat treated, the gear teeth are then precision ground to final dimensions. Precise gear grinding can be done with specialized equipment that produces ground gears of almost any size, from micro-gears up to huge, heavy gears for the mining or power generation industry. When it comes to gear grinding methods, there are two established techniques used by professionals. Each method has its own benefits and drawbacks. Here is a closer look at each one of them.

 

Continuous generating gear grinding

This technique uses a worm wheel that can either be ceramic or CBN with a diameter ranging from 100 to about 350mm. Its kinematics are similar to that of hobbing. It is most suitable for medium to large batch production. Generally, grinding times are shorter compared to profile grinding when ground gears are with Z>15 but longer with Z<15.

 

Profile gear grinding

The accuracy of the gears depends largely on the accuracy of the grinding wheel profile, which corresponds to the form of the tooth vane. Modifications can also be made when necessary to compensate for any possible interference between the gear tooth and the grinding wheel. The same applies to worm grinding, where the wheels can either be ceramic or CBN but with diameters of only up to 40mm. This makes it useful in gear grinding close to a shoulder. With this method, it is possible to grind profiles which are not involute such as rotors, splines, special worms, and so on. This option is perfect for small-medium batch production. With expert advice from True Gear’s technicians, you can rely on the best approach to your finished product. We can alternate the two methods on the same gear and within the same cycle. Using them allows us to provide significant reduction in grinding times and the improved quality of the gear manufactured. This can be particularly useful for low noise gear boxes and gear speed reducers.

 

True Gear and Spline provides gear grinding services using the latest technology and machinery, producing ground gears up to 1250 mm diameter and 1000mm face width. It enables us to have a competitive edge to serve all industries with top quality gearing, regardless of the size. Our advanced CNC gear grinding software and inspection capabilities enable us to meet the highest industry standards and customer specifications.  Contact us today to learn more.