Manufacturing of bevel gears. Gear cutting work (production of gears)
bring a broken one gear and according to this sample we make a new one, or according to the drawing, but then you need to know some parameters of the product such as (outer diameter, landing diameter, thickness, number of teeth, tooth angle, tooth module) A little about the material. Majority gear made by casting from various plastics 
it's cheaper and faster. PTFE is considered the best both in terms of fragility and degree of slip. But unfortunately it is not possible to glue it together, so it was replaced by such high-tech (but not cheap) materials as Caprolon (polyamide) and Zedex, and the first and second types of plastic have proven themselves very well in the role gears and various guides 
both in processing and material properties. Suffice it to say that Zedex is used in tanks as sliding bushings instead of bearings. So the lifespan of our products is no less than that of factory-made plastic, and in some cases much longer.
Manufacturing of gears– a complex multi-operational process requiring the use of special equipment. The specificity of performing operations implies an integrated approach, because all the stages that make up gear manufacturing, are closely interconnected, starting from design and ending with technical control of the finished product. The reliable and safe operation of the gear and its service life depend on the quality of individual operations. Only in factory conditions is it possible to accurately comply with all parameters of the production process.
In accordance with the design features, gears can be:
- conical:
- crowned;
- with hub;
- with roller;
- cylindrical:
- single-crowned;
- multi-crowned.
Spur gears are manufactured:
- with oblique teeth;
- with straight teeth;
- with chevron teeth.
For smooth and reliable engagement, the gear wheel must have at least 6 teeth - a gear. In everyday life, this name is fixed for all gears.
Manufacturing of gears carried out from:
- carbon steels;
- chromium steels;
- alloy steels (for highly loaded gears);
- some brands of cast iron.
The production of gears begins with the formation of a blank. The shape, size of the future wheel and material of manufacture determine the method of its manufacture. The most economical and less expensive are cold and hot stamping, hot heading, casting, hot rolling, punching, and powder metallurgy.
The next stage of gear manufacturing is cutting teeth on the workpiece by rolling or copying. Due to the low productivity and errors when cutting using the copying method, in large-scale production, preference is given to the rolling method. Roll cutting can be performed with a cutter, hob cutter, toothed rollers, cutter on gear planing, gear shaping and universal milling machines. The technical characteristics of the machines allow cutting internal and external wheel teeth, straight and oblique teeth with open and closed rims, and gear racks.
At gear manufacturing large and medium-sized teeth are cut after pressing the workpiece together with the shaft. After cutting the teeth, the surface is ground on gear grinding machines and hardened with high-frequency heat or in special hardening furnaces and polished.
Gear grinding and gear honing are finishing operations in the production of gears, intended to form the final appearance of the surface of products. If necessary, keyways or splines are cut into gears. Precise cutting, grinding and lapping of bevel gear teeth, the most complex and labor-intensive process, is performed on special CNC equipment.
To monitor the compliance of gear parameters, special devices are used: edge and optical caliper gauges. Due to the high requirements for product quality, the production of gears can be carried out with carburization of their working surfaces. Thanks to cementation, the required degree of hardening of products is achieved and the degree of their deformation is regulated.
Russian enterprises presented in the catalog are equipped with modern high-quality equipment from well-known foreign brands, which allows them to offer high-quality gear manufacturing any parties. Automation of production helps to increase productivity and reduce product costs. The production of gears is carried out in accordance with GOSTs and OSTs. Gear production can be carried out according to customer drawings or samples.
A convenient search system on the website will allow you to quickly and effortlessly find a company offering professional gear manufacturing.
The company's engineers have the necessary professional experience in design, calculations, design, production of equipment and tools, equipment adjustment, gear cutting work for the following types of mechanical drives and their parts:
You can find out the cost of supplying equipment/spare parts by sending a request/drawings to our e-mail: [email protected]
Experienced staff will advise on all services provided.
We offer realistic production times for orders.
Delivery times and method are discussed individually.
If you are interested and to issue an invoice for payment, please send your Customer details. We suggest you clarify the timing and delivery methods for receiving finished products in advance. Having received an invoice for payment and paying it after an indefinite period of time, inquire about the production deadlines.
The gear (or gear wheel, gearbox) is one of the most popular parts in equipment. It is necessary for transmitting rotational motion and is present in the vast majority of mechanisms. Gears are a disk with a cylindrical or conical surface on which teeth protrude at equal distances.
Gear manufacturing– a process that requires appropriate knowledge, qualifications and execution on specialized equipment. Gear cutting is carried out on gear milling machines of various modifications, distinguished by drive type. In the manufacture of gears, the following work is performed: calculation of adjustments, gear cutting with adjustment of the contact patch, gear grinding, lapping, hardening.
The material that will underlie the gear is selected depending on the subsequent operating conditions of the product. The main criteria that it must meet: increased wear resistance, good machinability.
We work with various grades of steel for the production of gears and gears. For the manufacture of bevel gears and bevel pairs, we suggest using the following grades: 18ХГТ; 12ХН3А; 20ХН3Ф; 40ХН2МА with subsequent heat treatment.
Helical gears. This is an improved version of spur gears, which is used in applications where it is necessary to transmit large torque at high speeds.
Circular tooth gears. The manufacturing process of such gears is much more complicated, but they have improved running characteristics.
Gears with pitch module. Pitch gear is mainly used in printing machines and food processing equipment.
Bevel gears. The production of bevel gears is carried out by the copying (division) method and the rolling method. The required dimensions for ordering this type of worm wheels must be indicated in the drawings.
Cylindrical straight teeth- the most popular type of gears. The contact line of the gear teeth is parallel to the axis of rotation, and the teeth continue the radii. An important requirement is that the wheel axes are parallel to each other.
Chevron wheels– will help solve the problem of axial force. The teeth are mated in an opposing manner and are shaped like the letter V. The mutual compensation of both parts of such a wheel is an additional advantage. Moreover, it is a self-aligning gear in the axial direction. These works are performed subject to the possibility of maneuvering the tool in the given specification.
We can prepare a commercial proposal by receiving drawings and assignments by email:[email protected]
- Address of the finished product warehouse: 107553 Moscow, st. Amurskaya 1 building 5/2,neighboring warehouse of shopping center "Business Lines", +7925-158-0623
- Finished products can be obtained by presenting an original power of attorney and passport.
- We suggest planning in advance for the purchase of spare parts; as usual, breakdowns occur unexpectedly; contact us; we are always ready to help restore and manufacture a wide range of industrial equipment.
#gearmaking
The Engineering Services Center "Modelier" produces all types of gears, gear rims, sprockets, as well as detachable spline connections.
We are ready to produce gears according to your sketches, drawings or product samples.
Manufacturing of gears
Gear manufacturing is a process that requires highly qualified employees and is performed on special equipment. Gear cutting usually produced with modular cutters on gear hobbing machines.
The Modelier Engineering Services Center produces various types of gears:
- helical gears;
- helical gear shaft;
- spur gears;
- bevel gears;
- circular tooth gears;
- gears with pitch module;
- gear racks;
- hypoid gears;
- cylindrical spur gears;
- ring gears;
- helical gears;
- chevron wheels;
- worm gears;
- gears with internal teeth;
- planetary mechanisms;
- plastic gears;
- toothed pulleys;
- production of stars;
- and other types of gears.
Custom Gear Manufacturing Methods
The Modelier Engineering Services Center produces gears in various ways:
- mold casting thus produces mainly plastic gears in mass production;
- rolling teeth on a gear;
- cutting teeth with special cutters;
- stamping, finishing, lapping, drawing;
- electrical erosion;
- 3D printing;
- swotting. Slotting usually produces helical or helical gears.
3D printing of gears Carbon fiber is typically used to repair equipment or make a prototype product.
The Engineering Services Center "Modelier" provides gear manufacturing of any complexity.
Usually for the manufacture of gears we use:
- carbon steel;
- alloy steel;
- chrome steel;
- cast iron;
- caprolon and fluoroplastic;
- bronze and brass;
- textolite;
- carbon (when printing a toothed mower on a 3D printer.
For the manufacture of gears according to the sample We use modern equipment and all possible international standards. Also we we produce sprockets for various equipment according to a sample or according to customer drawings.
Manufacturing of splined shafts and hubs
We produce movable split spline joints for various mechanisms, as well as spline-type parts that are used in equipment and machines. Splines on shafts provide transmission of high torque while being a detachable connection.
We produce splined shafts and hubs in our own production on CNC machines, and we also produce internal splines and produce splines on the shaft.
Manufactured spline connections
The Modelier Engineering Services Center provides:
- production of involute splines and bushings;
- production of straight-sided splines and bushings;
- production of triangular gear connections.
We use the following spline cutting methods:
- milling of spline teeth;
- rolling method (suitable for mass production of splines);
- slotting internal splines;
- drawing splines in bushings (is a very expensive and high-quality process);
- 3D printing of spline shafts and bushings.
- Electrical discharge machining of splines.
Cutting splines (slots) on a shaft is a rather responsible and labor-intensive process and requires highly qualified specialists and modern equipment with tools.
Making crowns
- this is a component of a usually collapsible gear wheel, which contains teeth of a certain size and is screwed to the wheel hub with bolts or using a permanent connection.
Center for engineering services "Modelier" manufactures various types of ring gears, namely:
- solid crowns;
- detachable ring gears;
- crowns with internal teeth;
- crowns with external teeth;
- chevron crowns;
- straight (straight-toothed) crowns;
- oblique (helical) crowns.
Application of ring gears
Ring gear is usually used for large diameter gears and gears that are difficult or impossible to manufacture entirely.
At the same time gear hub is manufactured made of a material with normal properties and a ring gear in the form of sectors is screwed or welded to it. We produce sector gears from various materials with heat treated and ground teeth.
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