Analysis of Diverse Gear Machining Processes
Involute tooth profiles are the most common; their manufacturing methods fall into two main categories: form-cutting and generating.
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Forming method : Includes gear milling (using disc-type module cutters or finger-type cutters, which offers relatively low machining accuracy and efficiency and is suitable for single-piece and small-batch production) and form grinding of gears (which is seldom used due to the difficulty of dressing the grinding wheel).
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Expansion Method : This is currently the mainstream machining method. Hobbing operates on the principle of meshing helical gears and is a widely used roughing or semi-finishing process; shaping corresponds to the meshing of cylindrical gears and is well suited for machining internal gears and compound gears; skiving is a common finishing method for non-hardened gear surfaces in high-volume production; and gear grinding is the primary finishing method for hardened gears, which can be performed using worm-wheel, tapered, or disc-shaped grinding wheels, effectively eliminating heat-treatment-induced deformation and achieving high precision. In recent years, 3D printing technology has also begun to be applied in gear manufacturing, providing a new approach for the rapid prototyping of gears with complex geometries.
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