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Gear Fabrication
Gear manufacturing is an important part of machines and mechanisms in industries. Gear systems are the basic components that enable the transmission of power and movement. These systems are commonly found in machines, vehicles and industrial equipment used in many sectors. Gear manufacturing is a complex process involving the production of high precision machined parts on specialised machines. This process, which usually involves the machining of metals, requires engineering calculations, the use of precision machinery and meticulous workmanship.
Gear manufacturing involves the production of various gear profiles. Different types of gear profiles, from simple gears to helical gears, bevel gears and screw gears, are produced according to industrial needs and mechanism requirements. This process involves material selection, dimensioning, machining, hardening and finally quality control of the gear profiles. Precise calculations and engineering know-how ensure that each gear profile is produced in the correct dimensions according to its specifications. This means that gear manufacturing is a critical factor determining the performance of machines and mechanisms.
Technological advances in the gear manufacturing process have enabled the production of more complex and durable gear systems. Computer-aided design (CAD) and manufacturing (CAM) software optimise the gear manufacturing process, while CNC machines and advanced machining techniques offer higher precision and repeatability. These developments make it possible to use more reliable and efficient gear systems in industrial applications.
Common Types of Gears and Their Applications
Before moving on to the details about gear cutting and manufacturing processes, it’s important to take a look at the basics. They are different types of gears and their application and advantages.
Your application, performance parameter, and numerous other factors play an important role in the kind of gears you use. There are several ways to characterize the type of gear, but the best and most relevant from a gear manufacturing perspective is through their teeth profile.
Here are the 5 kinds of gears you’ll encounter.
Spur Gears
Draw a rough picture of what gear looks like in your mind. There are high chances that you are thinking of gear with straight teeth. That’s exactly what a spur gear looks like.
The spur gear is the most common type of gear and has multiple applications in powerplants, aerospace components, industrial machines, and much more. Straight teeth are the simplest to manufacture and sustain at high speeds and in high loads. However, they produce a lot of noise and are unsuitable for applications where you need smooth operations. Furthermore, spur gears can mate with other gears of the same type and internal/external gears. You’ll find spur gears in many gearing mechanisms, like a simple rack/pinion setup or a planetary gear system.
Their simplicity means that it’s easier for you to make. Therefore, you’ll find it easier to maintain precision during gear production. Spur gears also have little to no axial load, so they are quite efficient for a gear train where you want to minimize mechanical losses.
Helical Gears
Helical gears are an important type used in gear systems. The gears ensure the transmission of power and movement. Helical gears have teeth cut at a diagonal angle compared to other gear types. These features allow for a quieter and smoother operation. Helical gears have more tooth contact area than spur gears, which means higher load-carrying capacity and lower gear wear.
Helical gear offers lower vibration and noise levels than other gear types. This makes them particularly favoured in machines operating at high speeds. Also, since helical gears have a lower interaction angle than bevel gears, they provide a smoother movement.
Helical gears are widely used in mechanical systems and industrial machines and offer high efficiency, low noise levels and a robust structure. In machines that usually operate under heavy loads, helical gears exhibit a long-lasting performance thanks to their durability and greater tooth contact area. With these features, helical gears have become an important component preferred in the power transmission of industrial machines and complex mechanical systems.
Bevel Gears
Bevel gears are gear types with teeth cut at different angles. These types of gears have teeth tapered along the gear wheel’s axis. Bevel gears are usually used at the intersection of two axes and are often used in power transmission or conversion.
These gears are used to provide angle changes, especially during power transmission. When coupled with another gear, it combines different gear axes to transform and transmit power. Bevel gears transmit the rotational motion of another gear in a different direction or at a different speed while providing power transmission.
Widely used in mechanical systems, bevel gears are often found in cars, differential systems, drill machines and heavy industrial equipment. They can be found in different angles and sizes, especially since they are used to change the direction or speed of rotational movement.
The structure and usage areas of bevel gears determine the performance and efficiency of gear systems. Although they have a more complex structure than other gear types, they work reliably and effectively when designed correctly. With these features, bevel gears have become important for power transmission and transformation in industrial and mechanical systems.
Here are some common types of bevel gears you can find in a variety of applications.
- Straight bevel gears
- Spiral bevel gears
- Miter gears
- Crown gears
- Hypoid gears
Worm Gears
A worm gear system combines a worm wheel and a screw-shaped gear. These systems are often used in different fields, such as aerospace, industrial machinery, lifts and automobile steering.
The worm wheel installation offers a special feature for self-locking mechanisms rather than providing high speed or efficiency. In most cases, the worm wheel can be turned, while the reverse may not be possible due to gear angles. Also another important point to note is that worm wheels have high friction and require constant friction to function properly.
Materials Used to Produce Gears
The material selection of gears is quite diverse, and models are available with different results. While wooden teeth are one of the oldest types, gears are available in various shapes, from steel or iron parts in industrial options to small plastic parts in toys. The variety of materials is generally endless.
However, the following headings are most commonly used in the production of parts and the details of their parts:
- Cast iron
- Steel
- Bronze
- plastics
Gears have very specific criteria for material selection. Depending on the application, it must have tensile strength and durability appropriate to the material.
Also, their values are important because the gears must be in constant contact. Finally, the machinability feature should also be considered because production can become a process with extreme precision and accuracy, especially with strong but low machinability features.
Custom Gear Fabrication Services
As NOVA Fabrication, we provide services for all your special (bespoke) projects, from small prototype work to large-scale gear manufacturing. Our company manufactures gears in accordance with international manufacturing processes (DIN, ISO, SEA).
As NOVA Fabrication, we provide services for all your special (bespoke) projects, from small prototype work to large-scale gear manufacturing. Gear manufacturing is a branch of manufacturing that requires expertise. Our company manufactures gears in accordance with international manufacturing processes (DIN, ISO, SEA). Our Gear Manufacturing services are as follows.
1.Standard Gear Manufacturing
2.Special Gear Manufacturing
3.Fason Gear Manufacturing
We use the Gear Design software KISSsoft to design all kinds of gear, gear groups and gearboxes (Gear Hobbing Machine) and produce them on 5 axis CNC machines.
The gear types we manufacture in our company are listed as follows.
- Straight Gear
- Helical Gear
- Herringbone Gear
- Spline Shafts
- Spline
- Screw Gear
- Bevel Gear
- Spiral Bevel Gear
- Zerol Bevel Gear
- Worm and Worm Gear
- Reductor
We can guarantee quality for all our work in the material and production process about gear manufacturing we offer you.
Heringbone Gear
Axial loads on the teeth balance each other mutually and therefore do not create axial load on the shaft. Sergeant gears are used to transfer large radial loads. Sergeant gear manufacturing is a type of gear production that requires expertise. We generally manufacture sergeant gear from gear manufacturing materials such as cementation steel, carbon steel, tempering steel, cast material and plastic. Sergeant gears are used in gear working environments that require high performance.
Spiral Bevel Gear
Since the Spiral Bevel Gear can touch more than one tooth at the same time, the gear strength is higher than the bevel gear. It has a lower sound level than bevel gear. Spiral bevel gears are used in gear mechanisms that require higher speeds. Spiral bevel gears are capable of operating at speeds up to 25m / s for average diameter circumferential speed. Since spiral bevel gears and helical bevel gears can operate at high speeds without noise, they are used extensively in other industries, especially automotive.
Straight Gear
Straight gear is the most basic and first known gear type commonly used in many industries. Straight gears are designed to transmit motion and power between parallel shafts. Straight gears are manufactured as steel straight gears, aluminium straight gears, cast straight gears, plastic straight gears, depending on operating conditions. Agricultural machinery is used extensively, including transmission gears and other sectors.
Helical Gear
Helical gears perform better than spur gears in terms of strength and silent operation and can operate at higher speeds. Helical gears are generally used in automobile transmission gears. The operation of spur gear wheels creates noise together with knocking in movement and force transmission as a result of the tooth surfaces touching each other along a straight line. To prevent this noise and knocking, gears are made as helix. Helical gears are used extensively in the industry, especially in oil industry gears and other sectors.
Worm and Worm Gear
The worm and worm gear are used to change the power transmission by 90 °. It is used to greatly reduce the high rotation speed at the worm and counter gear input at the output. Worm screws and counter gears operate less silently and with less vibration than other gear types. Since worm gears are used to reduce speeds, they are used especially in reducer boxes.
Products
✔ Forklift Gear ✔ Tractor Gear ✔ Agricultural Machine Gear ✔ Reductor Box Gear ✔ Grooving Machine Gear ✔ Truck Spiral Bevel Gear ✔ Machinery & Industry Gear ✔ Machine Tool Gear ✔ Textile Machine Gear ✔ Gearbox Spiral Bevel Gear ✔Heavy Equipment Gear ✔ Ship Spiral Bevel Gear ✔ Drilling ✔Machine Gear ✔ Printing Machine Gear ✔ Machine Shaft ✔ Reductor Worm Gear ✔ Valve Opening Screw ✔ Tapered ✔Thread ✔Vehicle Lift Shaft ✔ Reductors ✔ Turntables ✔ Dividing Heads ✔ Vehicles ✔ Crane Gear ✔ Rudder Mechanism ✔ Special Nut ✔ Dam Screws ✔Spiral Screws ✔ Dam Cover Screws
