How to choose the suitable gear processing technology of reducer

Accuracy requirements

High-precision gears: For example, gears in the fields of aerospace, precision machine tools, etc., usually require accuracy to reach IT5 or above, and generally use the grinding process. Grinding teeth can effectively correct the gear tooth shape and tooth direction errors and obtain high dimensional accuracy and surface quality.

Medium-precision gears: Most gears in the automotive, motorcycle and other industries have the accuracy requirements of IT6-IT7 levels, and can be processed using shaving, tooth insertion or hobbing processes. Shaving teeth can improve the tooth shape accuracy and surface quality, while inserting teeth and hobbing can meet general accuracy requirements and are more efficient.

Low-precision gear: For some gears that do not require high accuracy, such as gears in toys and simple machinery, simple processes such as milling teeth can meet the requirements. The milling teeth have low machining accuracy, but the equipment cost is low and the processing method is simple.

Material properties

Soft tooth surface materials: such as unquenched medium-carbon steel, medium-carbon alloy steel, etc., with low hardness, they can be processed using hobbing, tooth insertion, shaving and other processes. The cutting force of these processes is relatively small, and they can effectively process soft tooth surface materials and obtain better surface quality.

Hard tooth surface material: For gear materials with high hardness after heat treatment such as quenching, carburizing and quenching, such as high-carbon alloy steel, in order to ensure processing accuracy and surface quality, a tooth grinding process is usually required. Grinding teeth can overcome the high hardness of hard tooth surface materials and achieve high precision processing.

Production batch

Mass production: In industries such as automobiles and motorcycles, in order to improve production efficiency and reduce costs, efficient processing technologies such as gear hobbing and shaving are often used, and combined with automated production lines and special machine tools to achieve rapid processing and mass production of gears.

Small batch production: For single-piece or small batch production gears, such as gears in some special equipment and maintenance accessories, milling and tooth inserting processes with high machining flexibility can be used. These processes do not require complex tooling and fixtures, and the equipment adjustment is relatively simple and can meet the needs of small batch production.

Cost budget

Low-cost demand: If the cost budget is limited, for gears with low accuracy requirements, you can choose low-cost processes such as milling teeth and hobbing. These process equipment are relatively cheap and the tool cost is also low, which can reduce production costs to a certain extent.

High cost investment: For high-precision and high-performance gears and sufficient cost budget, high-precision processing technologies such as grinding are better choices. Although tooth grinding equipment is expensive and has high processing costs, it can ensure the quality and performance of gears and meet the requirements of high-end applications.

Equipment Conditions

Existing equipment: If an enterprise already has certain gear processing equipment, it should give priority to using existing equipment for processing. For example, if the enterprise already has a gear hobbing machine and a shaving machine, and the processing accuracy and efficiency can meet product requirements, then the gear hobbing and shaving process can be selected when producing the corresponding gear.