What is gear cutting process?

1. Milling

This is a common method. A milling cutter with a shape similar to the tooth space of the gear is used. The cutter rotates at a high speed, and the workpiece (the blank material for the gear) is fed into the cutter. As the milling process proceeds, the teeth of the gear are gradually formed by removing the excess material from the blank. For example, in a simple spur - gear milling operation, the milling machine operator precisely controls the feed rate and depth of cut to achieve the desired gear tooth profile.

2. Hobbing

It is a highly efficient and widely used gear - cutting process. A hob, which is a special cutting tool with a helical groove and teeth similar to a worm, is used. As the hob rotates, it simultaneously moves axially along the length of the gear blank, and the gear blank rotates at a synchronized speed. This coordinated motion between the hob and the gear blank gradually cuts the teeth of the gear around the circumference of the blank. Hobbing can be used to produce various types of gears, such as spur gears, helical gears, and worm gears.

3. Shaping

In gear shaping, a gear - shaped cutter (shaping cutter) reciprocates vertically while the gear blank rotates. The relative motion between the cutter and the blank gradually cuts out the gear teeth. This method is suitable for producing gears with internal teeth or gears in situations where hobbing is not practical, like when the gear has a complex structure or is located in a restricted space.

4. Broaching

For some gears with special shapes or high - precision requirements, broaching can be used. A broach, which is a long cutting tool with a series of successively larger cutting teeth, is passed through the gear blank. As the broach moves, each tooth removes a small amount of material, and the final tooth shape of the gear is formed when the entire broach has passed through the blank.