Analysis of the entire process of gear machining

Gear processing technology is the key to obtaining high-quality gears. The working conditions of gears determine the differences in their structure, shape, and accuracy level. In addition to different production conditions, the machining process of gears also varies. However, generally speaking, gear machining can be divided into four stages: rough machining, tooth surface machining, heat treatment, and tooth surface finishing.
Gear blank processing
Gear blanks are mainly forgings, bars, or castings, with forgings being the most commonly used. Gear blank processing plays a very important role in the entire gear processing process. The inner hole (or journal), end face, or outer circle of the gear blank is usually the benchmark for gear machining, measurement, and assembly. The accuracy of gear blanks has a significant impact on the machining accuracy of gears. It is necessary to normalize the rough parts to improve the cutting type and make it easier to cut; The margin control of the tooth blank is also important, as it increases the subsequent processing volume and reduces production efficiency. Minus; Special attention needs to be paid to the subsequent processing to ensure that the precision dimensions of gear machining are within the design range.
Surface treatment for gear machining
Gear processing should meet the requirements of gear design. Firstly, process the blank into a rough shape and retain the excess amount; Then, semi precision machining, turning, rolling, and gear forming are carried out to achieve basic gear formation. The surface treatment of gear machining can be divided into forming method treatment and generating method treatment.
1. Tooth surface forming method processing:
The surface forming method of gear machining refers to the use of forming tools to process workpieces. The gear manufactured using this method has low accuracy and can only be used in low-speed motion environments. The commonly used machining methods for forming include gear milling, gear shaping, gear extraction, and gear grinding, with the most commonly used being gear milling. Gear milling refers to the method of directly cutting gears on a milling machine using a special-shaped gear milling cutter. The characteristics of gear processing are convenient processing, low cost, but low productivity and accuracy.
2. Processing of gear machining surface development method:
Gear machining refers to the process of using workpieces and tools to generate cutting motion. He uses the meshing motion of the gear pair to achieve tooth profile cutting. The commonly used machining methods for generating gears are gear hobbing, gear modification, gear modification, honing, gear grinding, etc. Among them, the most commonly used are gear hobbing and gear modification. The processing method requires professional gear processing machines with high machining accuracy.
The heat treatment of gear processing directly determines the internal quality of gear teeth. The precision machining after gear processing and heat treatment is the key to manufacturing and also reflects the level of gear manufacturing. The quality of the heat treatment process will directly affect the strength, accuracy, noise, and lifespan of gears.
The working conditions of gears vary, and the failure forms of gear teeth also vary, which is the basis for determining gear strength, material selection, and heat treatment. At present, the main gear finishing methods used in industry are gear shaving, gear grinding, gear extrusion, gear grinding, and gear honing.