High quality processed gear wheels are used in many branches of industry and economy. Gear wheels can be produced in a variety of ways, with the most common methods being: casting; sintering; pressing; forging; rolling; punching; and cutting processes. Gear wheels can be easily manufactured using hobbing, profile milling, gear shaping, shaving, scraping, profiling, profile grinding, generating grinding, lapping, honing, as well as 5-axes milling and free form milling. These machining processes used for the production of gear wheels provide a high level of precision. Therefore, they are very commonly used in industry.
- Gears are needed in a large number of sectors
- Numerous diameter sizes require a monitoring process
- Commonly used in transmission and drive technology
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A bit later, EDM was also developed as a process that could be used. This is particularly suitable, when hardened workpieces should be processed into gear wheels. Gear wheels are often produced using 5-axes processing centres. Additionally, normal shank cutters can also be used and relied upon for tool profiling. This is particularly suitable for a small-scale series. In order to produce gear wheels using a processing centre, precise 3D-calculation models are necessary. Corresponding software modules for calculations are provided by operating manufacturers.
KAPP Gear cutting in use
Because of the numerous diameter sizes, monitoring processes belong within the gear wheel manufacturing process. Therefore, special gear wheel measuring systems have been developed. A machine tool for gear wheel processing using hobbing is built like a normal milling machine and uses specially profiled milling tools, depending on the internal modular pitch. An indexing head is commonly used for the clamping in of the workpiece, and then to move it into the next position. This process can be automatic and CNC-machines are available.