Gear machining is an extremely complex process. Only by using the right technology can efficient production be possible. Each part of the production process must also reach extremely precise dimensions.
The gear machining cycle includes ordinary turning → gear hobbing → gear shaping → gear shaving → hard turning → gear grinding → honing → drilling → inner hole grinding → welding → measurement. It is particularly important to configure a suitable clamping system for this process. Next, we will introduce the gear clamping system in each process.
1. Ordinary turning In ordinary turning, the gear blank is usually clamped on a vertical or horizontal turning machine. For automatic clamping fixtures, most of them do not need to install auxiliary stabilization devices on the other side of the spindle.
2. Gear hobbing
Because of its outstanding economy, gear hobbing is a cutting process used to produce external gears and cylindrical gears. Gear hobbing is not only widely used in the automotive industry, but also in the manufacture of large industrial transmissions, but the premise is that it will not be limited by the outer contour of the workpiece being processed.
3. Gear shaping Gear shaping is a process for machining gears, which is mainly used when gear hobbing is not possible. This processing method is mainly suitable for the internal gear processing of gears, as well as the external gear processing of some gears with structural interference.
4. Gear shaving
Gear shaving is a finishing process for gears, with a blade corresponding to the gear tooth shape during cutting. This process has high production economy and has been widely used in industry.
5. Hard turning
Hard turning makes it possible to replace expensive grinding processes. In order to make it work properly, the various parts of the system and the processing parts are connected together accordingly. The selection of the right machine tools, fixtures and cutting tools determines the quality of the turning effect.
6. Gear grinding
Today, in order to successfully achieve the required accuracy in gear production, hard finishing of the tooth surface is indispensable in many cases. In mass production, it is a very economical and effective processing method. On the other hand, similar to sample processing, when using adjustable grinding tools, gear grinding will show greater flexibility.
7. Honing Honing is a process for final finishing of hard gears using amorphous cutting angles. Honing is not only highly economical, but also can make the processed gear have a smooth surface with low noise. Compared to grinding, honing has a very low cutting speed (0.5 to 10 m/s), thus avoiding damage to the gear processing caused by cutting heat. More precisely, the internal stress generated on the processed tooth surface has a certain positive effect on the load-bearing capacity of the equipment.
Examples of honing with flange clamps:
8. Drilling Drilling is a rotary cutting process. The axis of the tool and the center of the processed hole are completely consistent in the axial direction and are consistent with the axial feed direction of the tool. The main axis of the cutting movement should be consistent with the tool and has nothing to do with the feed movement direction. Examples of drilling with SG clamping system:
9. Internal hole grinding Internal hole grinding is a mechanical processing process with amorphous cutting angles. Compared with other cutting processes, grinding has the advantages of high dimensional and forming accuracy for hard metals, dimensional accuracy (IT 5-6), small chatter marks and high surface quality (Rz = 1-3μm). Examples of internal hole grinding with film clamping SM system:
10. Capacitor discharge welding Capacitor discharge welding belongs to resistance welding process. Capacitor discharge welding is achieved by a very fast current increase, a relatively short welding time, and a very high welding current. Therefore, capacitor discharge welding has many advantages. With the increasing energy prices, the economic and efficient performance of capacitor discharge welding is particularly important. Case of capacitor discharge welding using welding fixture system:
11. The detection of gears is very extensive and must be adjusted according to the different forms of gears. In the measurement of gears, the various important parameters of the gears are determined by measuring the length, angle, and special gear process measurements.
