Gear Manufacturing Process

Gear manufacturing is today a multi billion dollar industry. As the demands of this industry is growing manufacturers are now increasingly seeking machining tools and technology that can meet with the tough challenges. As in this increasingly globalized world order manufacturers need suppliers that has global resources for delivering state-of-the-art machines, tools etc. Gears are now produced in near-net shape, with a cut in production as well as labour costs and elimination or reduction of wastes. These are also impacting the gear manufacturers to have greater freedom in the choice of materials.

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Steps in the Manufacturing Process of Gears
The gear manufacturing process is a complex step right from selecting the right material to finally doing the finishing process for getting an optimum quality gear. Gear blanks in the beginning are first roughed out and completely stress relieved this is done to minimise the distortion that have taken place after carburising. The blanks subsequently then undergoes the finishing process. Then the gear cutting process takes place giving allowance on the tooth flank for grinding. Then subsequently grinding and other steps takes place. Following are the steps in the gear manufacturing processes:      

Wire Cut EDM(Electro Discharge Machine)

Wire-Cut EDM
The wire-cut produces gear shapes by cutting the metal gears with a continuously moving wire. Which operates with rapid, repetitive discharges. This process is used to cut gears that are very thick and intricate. In the following image the gears are machined into two pieces by using wire EDM.