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What You Should Know About Gear Manufacturing All production processes are geared towards creating added value. In gear manufacturing, the creation of benefit focuses on achieving QCD (costs, volumes, and deadlines). As such, the production of gears involves a combination of processes. Process used in the manufacture of gears include blanking, forging, powder metallurgy, extrusion, and casting. Gear manufacturers produce different kinds of gears for use in different industries. Examples of gear types include bevel gears, worm gears, spur and helical gears. Gear manufacturers classify gear types by the positioning of intersecting shafts, parallel shafts, and non-intersecting shafts. Understanding the differences between gear types is critical in understanding how force is transmitted in different mechanical configurations. When selecting gears, you are required to evaluate a variety of factors. Advances in gear manufacturing technology have made it easier for manufacturers to produce stock or custom made gears. Today, machines exist which facilitates entire production processes. The gear manufacturing process can be automatic, semi automatic, or manual. Machining is the most common process used that utilises shaping or hobbing techniques. Large volumes of gears are manufactured using machine based techniques. Hobbing employs dedicated machines to make gears by relying on vertical or horizontal spindles In hobbing, a gear blank is moved towards a rotating hob until the proper depth is achieved. After the right gear depth is attained, the blank is then passed through a hob cutter. Grinding employs a gear cutter to achieve the required gear design and type. Mostly, grinding is used to finish accurate and hardened gears. Gear grinding is slow and is only utilized for the manufacture of high quality hardened gears.
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Quality manufacture of gears requires a working knowledge of the mechanical properties of materials used in production. It is equally true where production depends on standardized designs. Production requires engineers to understand factors such as rotational directions, drive train speed ratios, the different kinds of gears, their sizes, and strengths. Other factors that affect the production process include ISO and AGMA classifications, teeth forms, teeth thicknesses, and backlashes.
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Designing gears, therefore, relies on industry standards for improving quality and performance. These benchmarks entail the evaluation of a manufacturer’s critical production functions and key engineering processes. Reverse engineering gears is commonly employed to benchmark production facilities Reverse engineering entails the computation of design parameters for the specific gear type. Despite gear calculations and parameters being standardized, the task is often complex. However, in most instances, the accuracy of reverse engineering can be improved substantially. The process requires the performance of repetitive procedures to arrive at conclusive data. Acquired measurements provide information regarding design deviations, uncertainty in measurements, and wearing of gears in the application environment.