Question

What methods can be used in gearwheel production without chip removal?

Answer 1

Answer:

Gears are very important part of human daily life and these are used for transmission of mechanical power from one point to another point. They are the most important parts of any transmission system. So during manufacturing of gear wheels it is required to maintain very high precision so that highest possible efficiency work transmission can be obtained. There are different traditional as well as some new technologies which can be used to produce gear wheels.All the technologies and methods which are used for making gear wheels are as given below and in all the processes there is no removal of chips.

Casting:

Depending upon the various surface finish and different teeth requirement different types of casting processes are used for making gear wheels as well as gears.It is a old process of making gears and still being used and different casting processes which are used are as given below:

• Sand casting is used for making big and large cast iron gears in which exact replica patterns are made and the gears and gear wheels are produced.
• Metal mould casting is the other casting process which is used to make medium sized gears made of steels.Finishing and accuracy acheived by this process is not enough so that these types of gears made by this process are used in agro industries.
• Die castings are used for mass production of gears and gears wheel made of aluminium,zinc, copper and magnesium.High finishing is acheived with the help of this casting process and gears made by this process is used for light load applications
• Investment casting process is used for high accuracy and precise gears manufacturing. Gears produced by this process are used in low to medium load appliations and with higher surface finish so that thee is no furthie need of finishing.
• Shell moulding technique of casting is used to produce the gears in batched.Qulaity of the gears which is acheived by this process is in between that of sand casting an dinvestment casting.ο
• Centrifugal casting process is generally used for the cast iron, phosphor bronze and steels. Different size gear wheels can be produced with the help of this casting process

Gear rolling:

It is a new technique with which the gear wheels can be produced. Generally gear wheels produced with this method are used in low module gears production. Flat and round rolling is used to produce the gear wheels and the steps used in these processes are as given below:

• In the very first step there is small amount of engagnment betweeen roolers and workpiece which is cause by the pressure applied to the rollers. With the rotation of rollers which have the shape of gears gives the small impressions on the gear wheel. After several rolling passes gears starts developing.
• In the second step plastic material flow is acheived by penetrating the rollers more inside the workpiece by applying more pressure.
• After the full penetration is acheived,penetration is stopped and calibration is carried out to make the teeth with high precesion
• Powder metallurgy:

Very high accuracy and precise gears ar produced with the help of powder mettalurgy process with the minimal defects. Spur, and bevel gears can be produced as well as intrnal and extrnal gears are also can be produced with the hlp of this process. There is no furthur finishing is required after the gear wheels which are produced by powder metallurgy process. Strength also good due to sintering process

• Press tool balnking:

By designing the suitable die and punch, less accurate and precise gears are produced with the help of this process.

• Plastic moulding process:

With the help of injection moulding process, large quantity of mediu sized plastic gears can be produced with the help of thisprocess without removal of any material in form of chips. Both external as well as internal type of gears used for light load applications can be produced with the help of this process

• Extrusion process:

High quality of gears and gears wheel are produced with the help of this process. Extranl gears mainly are only produced which can be metallic as well as non metallic. Desired shape and size can be acheived by this process of gear wheel manufacturing

• Wire EDM process

So all these process shown above are the process or methods used for producing gear wheels or gear without removal of material in form of chips.