Manufacturing of gears and gears. Gear cutting work (production of gears) Manufacturing of gears to order

— a separate technological process of metalworking, the manufacture of mechanical gears is carried out on specialized equipment. We always strive for the highest quality - production of mechanical gears and industrial gearboxes. We will calculate the cost of manufacturing gears and delivery times within one day; complex projects take longer to calculate. We guarantee factory quality and compliance with the drawings of the supplied equipment and spare parts.

Manufacturing of gears according to drawings, supplies - mechanical drives:

Helical gears. This is an improved version of spur gears, which is used in applications where it is necessary to transmit high torque at high speeds.
Gears with circular teeth. 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, bevel gears, bevel pairs.
Spur gears are 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 carried out under the condition that the tool can be maneuvered in the given specification.
Spur gears with internal teeth.
Bevel gears.
Hypoid pairs, hypoid gears, hypoid gears.
Reducer gears.
Planetary gears.

In the manufacture of gears, we also use grinding and thermal equipment, the presence of which, along with extensive practice and deep knowledge, helps to carry out a wide range of work on the manufacture of gears and mechanical transmissions.

Using the accumulated experience and knowledge in the production process of gears, we offer the best conditions for the supply of the above mechanical gears.

We offer the fastest possible cost calculation for further production of gears on our own equipment. The company's engineers and mechanics have extensive experience and the necessary knowledge in the design and manufacture of mechanical transmissions.

Also, the production time for gears depends on how quickly the workpieces arrive at the production site. The Tokarmet company has a constant presence in its warehouses of various grades of steel and configurations of blanks and forgings. Warehouse stocks allow us to eliminate the time for purchasing and delivering blanks to production. Tokarmet offers terms and prices for production on the day of the request or the next day after receiving the drawings for calculation.

We invite suppliers of forgings to cooperate.

Quality guarantee for gear manufacturing

We guarantee a responsible attitude towards the production and supply of gears and metalworking orders - for any industry. Work on samples often takes more time for calculations, selection of tools, delivery times for samples may take longer than the agreed period. We try to ensure that our customers' machines are restored to working condition and working as quickly as possible. We offer high-quality solutions and service for the production and supply of spare parts and equipment!

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-crown;
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.

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LLC Plant Spetsstanmash carries out gear cutting work, through which the following types of gears are produced:

gears with a circular tooth (manufactured only in pairs);
spur gears (modulus from 0.25 to 12);
gears with internal teeth (gear couplings);
helical gears;
gear shafts;
planetary mechanisms;
gear racks;
plastic gears (for office equipment, ATMs, coffee machines, vending machines, etc.);
toothed pulleys;
worm wheels made of bronze (a counter worm shaft is required);
stars.

Order the production of gears from LLC Plant Spetsstanmash

LLC Plant Spetsstanmash manufactures gears according to individual drawings or customer samples.

We offer a unique service - our craftsmen and engineers will visit your enterprise to take all the necessary measurements if you are unable to provide visual material.

Our plant produces gears of the highest quality in compliance with all your requirements. The enterprise is equipped with progressive, high-precision equipment, which allows us to carry out work of any complexity and varying volumes, while meeting all customer requests. When manufacturing products of any size, we rely on the requirements of drawings, and in their absence (if only samples are provided) - on the relevant reference books and GOSTs, and also take into account the purpose of the parts, operating conditions, carry out hardness measurements, and, if necessary, chemical analysis of the material. If the requirements of the drawing are clearly overestimated or underestimated (do not correspond to the general nature and purpose of the part or operating conditions), then with the consent of the client, appropriate adjustments are made - this saves money and production time, or extends the life of the parts.

Prices for services:

* Orders are accepted from 1 piece
* You can find out the exact cost using the form or by phone
* Minimum order amount - 3500 rubles

The cost of producing products depends on the following two factors:
1) production time and 2) order volumes.

Products are delivered throughout Russia: in Moscow and the European part of the country - within three days, to populated areas of Siberia and the Far East - no more than ten days.

In addition, we manufacture gears with a pitch module (non-standard tooth): 1.01; 1.59; 2.02; 3.17, etc. These products are intended for loaders, printing machines and other foreign equipment.

Application of gears

The synchronicity of the operation of the entire mechanism and the duration of its operation depend on how well the gears were manufactured. This product is used in gear mechanisms and performs an important function - it transmits rotational motion between shafts. Defects in manufacturing can lead to vibration and loss of synchronicity in the functioning of the entire device, up to its failure.

The production of sprockets, toothed pulleys, worm wheels and other types of gears is necessary for use in various mechanisms that are used in the mining and food industries, shipbuilding and mechanical engineering. Gears are also actively used in automobile differentials, drilling rigs, winches, railway cars, cranes, tanks, gearboxes, gear hydraulic machines - clocks, pumps and other mechanisms.

It is important to note that gears differ not only in the method of cutting the teeth, but also in shape, therefore, when manufacturing them, the surface of the parts is also taken into account, which can be:

conical;
cylindrical.

Examples of gear cutting work

Gears and cogwheels can be used to create a wide variety of mechanisms. Their geometric features determine the ability to provide reliable engagement for transmitting force. The technology for manufacturing gears is characterized by a fairly large number of features, among which we note the use of special equipment. If the manufacture of gears is carried out without taking into account the geometric features, then the quality of the resulting connection for transmitting rotation is significantly reduced.

Gear design

There are simply a huge number of varieties of gears, all of them are characterized by their own specific features. Among the design features, we note the following points:

In the manufacture of cylindrical and bevel gears with straight teeth, the working part is created integrally with the shaft. This is due to the fact that the dimensions of the structure are significantly reduced. By creating such a design, it is possible to obtain a part with high accuracy and wear resistance.
There are also pinion-type gears. They are very common when the diameter of the working part is large. Due to the installation of a mounted version, it is possible to carry out maintenance of the structure.
With a diameter of less than 500 mm, the product is produced by forging and casting, as well as by using welding technology. Options larger than 500 mm are manufactured using casting and welding methods.
Riveted or rolled wheels can be installed if there is a need to save the material used.

The most widespread are cylindrical gears.

The design features of this version can be called:

A disk of a certain thickness is used as a workpiece.
In the central part there is a mounting hole with a slot for a key. As a rule, it has a fairly large border.
The working part is represented by teeth, which can be located straight or at an angle. In this case, the geometry of the tooth can differ significantly, it all depends on the area of operation.

The production of cylindrical gears is carried out using special equipment. An example is gear cutting machines that operate using the rolling-in method. It is worth considering that the manufacturing process of bevel gears is significantly different.

Basic manufacturing methods

Blanks for the products in question are obtained by forging or casting, in some cases using cutting technology. The design of a gear wheel is quite complicated, since it is necessary to obtain a working surface of complex shape with certain geometric parameters. Helical wheels and other products are cut using two main technologies:

The copying method involves milling, in which a cut between the cavities of the teeth is formed by using disk, modular or end mills. After each cavity is formed, the workpiece is rotated exactly one tooth. Among the features of this technology, it can be noted that the shape of the cutting tool used follows the shape of the cavity.
The break-in method is much more common today. In this case, machining involves simulating the engagement of a gear pair, one element of which becomes. In the manufacture of the tool, high-strength metal is used, due to which cutting occurs. Processing by the copying method involves the use of not only a hob cutter, but also a cutter and a comb.

Hob cutters have become quite widespread. A similar tool is represented by a rack; at the time of operation, the workpiece rotates around its axis. The tool is used to produce exclusively gears with external teeth.

The combs are used for cutting straight and oblique teeth with a high gearing modulus. It is worth considering that the surface of the tool can wear out quickly.

Rolling technology is used to produce large gears as well as large quantities. In this case, hot rolling is carried out; due to heating, the degree of workability of the material increases. The crown is obtained by extrusion. To significantly improve accuracy, mechanical processing can be carried out.

The manufacture of shaft gears must also be carried out taking into account operating conditions. There is a high load on this element, so a workpiece made of high-strength hardened steel is used as a base. The toothed gear, the manufacture of which is carried out taking into account the diameter of the shaft, is mounted using the pressing method, fixation is ensured by a key.

Preparation of drawings

The manufacturing process begins with the immediate preparation of the drawing. In this case, production is significantly simplified, and the accuracy of the resulting product is significantly increased. When developing a drawing, the following information is indicated:

Bore hole diameter. For gears, corresponding shafts are made, which have a certain mounting diameter. This indicator is standardized and is selected depending on the size of the product and the amount of force applied.
Key sizes. The key hole can be very different; the dimensions are selected depending on the loads that will be applied. It is worth considering the fact that the sizes of the keys are standardized.
Module. This parameter is considered the most important, since an erroneous module can reduce the performance of the mechanism.
The outer and inner diameters that determine the size of the tooth. It is worth considering that this element of the product is characterized by a fairly large number of features.
The angle of the tooth relative to the axis of rotation. There are gears with straight and oblique teeth.

The production of gears of any size is possible only with the use of special machines that are designed to solve the task.

Technological tasks in the production of the product in question may differ significantly. Important points include the following:

Dimensional accuracy. The hole that acts as a seat for the shaft has the most accurate dimensions. In most cases, it is manufactured according to the 7th quality if there are no more requirements for the product.
Form accuracy. In most cases, when manufacturing gears, there are no special requirements for shape accuracy. However, the mounting hole must be located in the central part of the product, since even a slight displacement can lead to the inability to use the product.
Relative position accuracy. The greatest demands are placed on the way the teeth and other structural elements are positioned relative to each other. If the geometric shape is violated, there is a possibility of a runout effect and other problems during the operation of the product.
Hardness of the working surface. The main requirements are related to the hardness of the working surface. The gears are constantly in contact, the frictional force can cause rapid wear of the surface. To obtain the required hardness index, heat treatment is carried out. The recommended value is HRC 45...60 with a cementation depth of 1-2 mm. As studies have shown, the hardness of the unhardened surface is HB 180-270.
Choosing the right material also matters. Depending on the application of the product, they can be made of carbon, alloy steels and plastics, and in some cases cast iron. Alloyed ones, in comparison with carbon ones, are characterized by greater hardenability, as well as a lower tendency to deformation. The material used must be characterized by a homogeneous structure, due to which the strength significantly increases after heat treatment. In the manufacture of high-precision products, alternating mechanical and thermal processing is carried out.

Technological process

The gear manufacturing process on large production lines is as automated as possible. The classic technical process is characterized by the following features:

To begin with, the basic parameters of the product are determined, for example, the number of teeth, modulus and degree of accuracy of geometric dimensions.
The next stage is to carry out the procurement procedure. Most often, stamping is carried out using a horizontal forging machine.
To improve performance, normalization is performed. Such heat treatment reduces stress inside the material.
The turning-screw-cutting procedure allows you to obtain a workpiece of the required dimensions. To do this, surface turning and chamfer boring are performed.
After machining the spur gears, re-normalization is performed.
The workpiece is subjected to gear hobbing. For this, a semi-automatic 5306K or other similar equipment is used.
The next step is metalworking. The technological process determines the appearance of burrs and other defects, which are eliminated when using the 5525 semi-automatic machine. On lines with low productivity, cleaning is carried out manually.
After obtaining the teeth, heat treatment is performed, for which a HDTV installation is often used. Hardening can significantly increase surface hardness and wear resistance.
Surface grinding. To obtain the surface of the required quality, grinding is performed. There are quite a lot of different equipment that are suitable for sanding a wide variety of surfaces.
Mounted gears have become widespread. They are mounted on a shaft and can be of large or small sizes. The attachment version is fixed using a key. You can obtain a keyway by using a slotting machine.
Gear grinding is also carried out using special machines.

It is worth considering that plastic gears are made using only one machine. This is due to the high degree of processability of plastic.

In conclusion, we note that the gear hobbing procedure is quite complex and requires the use of special equipment.

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We have a fleet of CNC-equipped equipment, including lathes, milling and gear cutting machines. Having a fully equipped production facility, we can quickly resolve a number of issues related to single orders such as gears.

In most household and office equipment, the mechanisms are built on plastic, less often caprolon gears. It is often very difficult, and sometimes simply impossible, to purchase a new one to replace a broken gear. We will help you with the restoration or production of a new gear according to the sample that you will need to provide to us.

We work both with private clients and with service centers and repair shops. One of the common conditions for fulfilling orders in such cases is the fulfillment of one-time orders for the production of gears in small series for a certain type of equipment. There are dozens of “unsuccessfully” produced models, for example, shredders in which in 100% of cases the same gear fails when broken. Under such conditions, we will produce a small batch of gears for you based on the original sample, which will be significantly lower than the cost of a one-time order, and you will always have a spare gear on hand.

Gears and gears can be made either according to drawings, sketches or parts of a gear wheel (for example, a broken one).

The approximate production time for a component is from 1 to 3 days; in the case of a small batch, the time may increase to a week.
We manufacture gears: bevel, helical, spur, planetary, internal gears, sprockets for chain drives.