Machining the production of double spur gears is a challenging and high-precision process. Double spur gears are often used in mechanical transmission to achieve complex speed changes and power transmission, such as in some heavy-duty machinery and high-precision machine tools. In terms of material selection, high-strength and wear-resistant alloy steels such as 40Cr or 20CrMnTi are usually used to meet their load-bearing and wear resistance requirements during operation. The manufacturing of rough parts is generally achieved through forging or casting, followed by rough machining to preliminarily form the shape of gears.
For the tooth profile machining of double spur gears, common methods include:
Gear hobbing: Using a gear hobbing machine and a suitable hob, accurately cut the tooth profile of the gear according to the principle of generation. In this process, it is necessary to strictly control the parameters of the hob and the motion accuracy of the hobbing machine to ensure the tooth profile accuracy and relative position accuracy of the two teeth of the double spur gear.
Gear shaping processing: For some special structures or parts with high precision requirements, gear shaping technology may be used to supplement processing.
During the machining process, precise clamping and positioning are required to ensure the coaxiality and phase relationship between the two teeth. For example, using specialized fixtures and high-precision measurement methods, real-time monitoring of dimensional and positional deviations during processing.
Heat treatment is also a crucial step, usually carried out through carburization and quenching or tempering to improve the hardness and comprehensive mechanical properties of gears.
After completing the heat treatment, precision machining processes such as gear grinding will also be carried out to further improve the accuracy and surface quality of the tooth surface.
In the main transmission system of high-end CNC machine tools, the accuracy and performance of double spur gears directly affect the machining accuracy and stability of the machine tool. Therefore, in the machining production process, every step needs to strictly follow the process specifications and quality standards. Machining and producing double spur gears requires advanced equipment, exquisite craftsmanship, and strict quality control to meet their high-performance requirements in various complex mechanical transmission systems.
Using CNC (Computer Numerical Control) machine tools to produce gears is an efficient and accurate manufacturing method. The following are the general steps for producing gears using CNC machine tools:
Design gears: First, you need to use CAD (Computer Aided Design) software to design gears. This includes determining key parameters such as the number of teeth, modulus, pressure angle, and tooth width of the gear.
Programming: Then, you need to convert the CAD design into code that CNC machine tools can understand. This is usually accomplished through CAM (Computer Aided Manufacturing) software. CAM software can convert CAD designs into G code or M code, which are instructions used by CNC machine tools to guide the machining process.
Choose cutting tools and fixtures: Select appropriate cutting tools and fixtures based on the material and design of the gear. Cutting tools are used to remove excess metal, while fixtures are used to fix gears on CNC machines to ensure stability during the machining process.
Set up CNC machine tool: Install the cutting tools and fixtures on the CNC machine tool, and adjust the parameters of the machine tool according to the gear design, such as cutting speed, feed rate, cutting depth, etc.
Start machining: Start the CNC machine tool and start the machining process. CNC machine tools will automatically perform cutting operations based on programmed instructions until gear machining is completed.
Inspection and testing: After the machining is completed, it is necessary to inspect and test the gears to ensure that their dimensions, accuracy, and performance meet the design requirements. This can be achieved by using various measuring tools and equipment, such as calipers, micrometers, gear measuring instruments, etc.
The use of CNC machine tools to produce gears has many advantages, including high precision, high efficiency, repeatability, and flexibility. CNC machine tools can be programmed and adjusted as needed to produce gears of different sizes, shapes, and materials. In addition, CNC machine tools can also achieve automated production, reduce labor costs, and improve production efficiency.
In the realm of precision gear manufacturing, we’ve embraced CNC machining as the cornerstone of our process for crafting double spur gears. These specialized components, featuring two sets of teeth on a single shaft, play a vital role in various mechanical systems, from industrial machinery to automotive transmissions. Our approach to CNC machining ensures that each double spur gear we produce meets the highest standards of accuracy, durability, and performance.
The journey begins with a deep understanding of our clients’ needs. We collaborate closely with engineers and designers to grasp the specific requirements of each double spur gear project. Whether it’s for a high – torque application or a precision instrument, we take into account factors such as gear ratio, load capacity, and operating environment. Using advanced computer – aided design (CAD) software, we create detailed 3D models of the double spur gear. These models allow us to visualize every aspect of the gear, from the tooth profile and pitch to the spacing between the two sets of teeth. We simulate the gear’s performance under various conditions, making adjustments to optimize efficiency and minimize wear.
Once the design is finalized, we turn our attention to material selection. The choice of material is critical to the gear’s performance and longevity. For most double spur gears, we opt for high – quality alloy steels, which offer excellent strength and wear resistance. However, depending on the application, we may also use other materials such as stainless steel for corrosion resistance or aluminum for lightweight designs. We source our materials from trusted suppliers and conduct thorough inspections to ensure they meet our strict quality standards. The raw material is then prepared for machining, typically by cutting it to the appropriate size and shape.
Setting up the CNC machine is a meticulous process that requires precision and attention to detail. We carefully select and install the appropriate cutting tools, such as hobs and end mills, ensuring they are properly aligned and calibrated. The prepared raw material is securely mounted on the machine’s workholding device, which may include chucks, collets, or fixtures designed specifically for gear machining. We then program the CNC machine using computer – aided manufacturing (CAM) software, which converts the 3D design into a series of precise instructions for the machine. This includes specifying the cutting paths, speeds, and feeds required to produce the double spur gear with the desired accuracy.
The machining process itself is a complex and multi – step operation. We begin by roughing out the basic shape of the gear using turning operations to create the cylindrical body. Next, we use hobbing to cut the teeth on both sets of the double spur gear. Hobbing is a highly precise process that involves using a rotating hob tool to generate the teeth with the correct profile and spacing. This step requires careful coordination between the rotation of the workpiece and the movement of the hob to ensure accurate tooth formation. Depending on the design requirements, we may also perform additional operations such as milling to create keyways or flats on the gear shaft.
Quality control is an integral part of our manufacturing process. At every stage, we monitor the production to ensure that the double spur gear meets our strict specifications. After machining, we use a variety of inspection tools and techniques to verify the accuracy of the gear. This includes measuring the dimensions of the teeth, checking the tooth profile using specialized gear measurement equipment, and inspecting the surface finish for any defects. We also conduct hardness testing to ensure the material has been properly heat – treated to achieve the desired properties. Any gear that does not meet our quality standards is rejected and reworked or scrapped.
Once the double spur gear has passed all quality checks, we proceed with any necessary finishing operations. This may include heat treatment to improve the gear’s hardness and strength, followed by grinding or honing to achieve the required surface finish and dimensional accuracy. We also apply protective coatings or treatments to enhance the gear’s resistance to corrosion and wear. Finally, the gear is cleaned, inspected again, and prepared for packaging and shipping.
In conclusion, manufacturing double spur gears by CNC machining is a complex and precise process that requires expertise, advanced technology, and a commitment to quality. By following these steps, we are able to produce double spur gears that meet the most demanding specifications and provide reliable performance in a wide range of applications. Our dedication to excellence ensures that every gear we manufacture is a testament to our skill and commitment to precision engineering.