Gears are mechanical components that have been used by mankind for a long time. These toothed elements have mechanical properties that are used to convey motion and power among machine components. From bicycles and cars to modern industrial machines, instrumentation, and equipment, gears find a wide range of applications in aircraft, automobiles, power plants, marine systems, and more! Earlier, these tools were a bit complex to manufacture. Thanks to the advanced CAD system and CNC machine system, the production of gears is more precise and faster than before!
Here, we’ll get you through the entire gear manufacturing process and the role of CNC machining.
What Goes into Gear Manufacturing Process?
Gears come in many configurations, i.e., spur, bevel, or helical gears. All these types of gear are generally found in aerospace, automotive, or other motor industries. They have applications in almost every modern machinery. Thus, gears should have robust construction and offer high efficiency, great performance, and durability. Based on these unique requirements, manufacturers use different materials to manufacture gears. Some gears are made of steel, while others are of non-ferrous materials.
Furthermore, gears are manufactured through many different processes, like Forging, Casting, Powder Metallurgy, or Blanking. Amongst these, Gear Machining is the most common manufacturing method.
Gear Machining: The Most Common Gear Manufacturing Process
Gear machining is a set of processes by which gears of different shapes are manufactured from raw materials. In this process, the material is filed and sculpted until the required shape and characteristics are obtained. Gear machining is divided into two categories-
Generally, cut gears are manufactured via a gear-generating method. In this method, gear cutting is done via a relative motion of a rotating cutting tool and rotational motion of the workpiece. Hobbing and Shaping are the two common gear generating processes.
Hobbing refers to a continuous machining process on a hobbing machine. A cutting tool called a hob is used to make a series of cuts into a workpiece. This method offers good precision when it comes to cutting gears, splines, etc. However, this process is limited to creating external gear teeth only.
Gear shaping uses a reciprocating tool called ‘shaper cutter’ to create a part. This process can be used to cut both internal and external gears. Moreover, it requires a small clearance; thus, it can be used to cut gears that hobbing can’t. This process is slow as compared to hobbing, though.
In this process, cutting tools with actual shapes (desired in the final product) are used. Broaching and Milling are the two most common form-cutting methods.
Broaching is the fastest method of machining gears. It is extensively used to fashion the gears into levelled structures by removing excess material from them. It redefines the odd shapes of gears.
The gear milling process involves the use of a milling machine for creating almost any type of gear. Traditionally, manufacturers used a form cutter for producing gears. This method is now outdated due to its low precision. However, recent CNC modeling improvements have empowered gear milling, resulting in the use of standard milling tools with sophisticated CAD programs.
What Is the Role of CNC Machining in Gear Manufacture?
Manual methods of the gear manufacturing process, like cutting or hobbing, have been relied on for years. In fact, knowledgeable and skilled operators were able to achieve fantastic results. But CNC precision machining has revolutionized the gear and spline business. Below is what makes custom machining ideal for gear part fabrication-
Improved Speed and Quality
With CNC machining, you get the same result as specified, at a faster speed. Unlike manual methods, the speed of production is high, streamlining the production process. Further, CNC machining offers a lucrative option for a larger production. Though a skilled operator can replicate the same quality, CNC machining lets you assess the production rates and quality better.
No Need for Prototype
With CNC machining software, one can visualize the finished products before they are made. A finished product designed on a computer eliminates the need for a prototype.
CNC machining, Machine tools control panel offers ways for monitoring the progress of gear manufacture remotely. Thus, manufacturers can keep track of their projects and keep an eye on every detail. Though it requires experience, the level of skills and overall user involvement is still less compared to the traditional gear cutting methods.
Precision is a paramount consideration when it comes to gear manufacturing. Factors like gear variations, high accuracy, etc., make the process a bit complex. However, by picking the right solution, the quality and productivity can be improved while saving a lot of time and effort.
Motor drives are the spine of a new global industry. They are often hidden but play a vital role in industries and our way to live a more sustainable life. Nowadays, the most frequent usage of drives is for the controlling of fans, pumps, and compressors. About 75% of all drives work globally on these applications.
Sourav (CEO of CM Industry Supply Automation) says Motor drives are also referred to as AC drives, VFD (variable frequency drives), adjustable speed drives, VSD (variable speed drives), and adjustable frequency drives, inverters, frequency converters, and power converters. By changing the voltage and the frequency of the power supply to an electrical motor, drives are able to control their speed and improve process control, cut down energy usage and make energy-efficient. In addition, industrial drives optimize the working of various applications that relies on electric motors.
Drives have the capability to control ramp-up and ramp-down of a motor while set up or discontinuing respectively. This reduces automatic stress on motor control applications and enhances ride quality in, such as elevators.
Motor drives are also useful for converting energy from natural and renewable resources such as the wind, sun, and tides, and spreading it to the electrical network or utilizing it for limited consumption. Industrial motor drives are also utilized to merge conventional energy sources and energy storage for creating total energy management solutions, in hybrid technologies.
Drives are a vital part of various industrial processes. They provide good energy efficiency, enhance productivity, and great performance for electric motors in various applications. However, when an industrial drive breaks down suddenly, it can bring working to a halt and cause many problems.
The best way is to prevent a breakdown before it takes place. During the life cycle of the product, this usually means usual preventive maintenance. However, for an industrial drive at the end of its life cycle, repair or replacement is a good solution to minimize the risk of breakage and accidental production shutdowns.
How old is your Industrial drive?
When you are thinking about whether to repair or replace the industrial drive, it is crucial to consider the drive's age and what's it phase right now. Lenze drive lifecycle falls into various phases. Since your drive passes on through each phase, parts become complex or not easy to obtain. Moreover, the advancement in drive technologies results in your application not having the latest features and functionality.
Do you want to know where your drives are within their lifecycle? CM Industry Supply Automation has access to the complete drive database of many brands such as Lenze, KEB, Siemens, Rexroth, Elau, ABB, Allen-Bradley, and more.
All you have to do is share the serial numbers of your drive population with us, so we will register them and tell you precisely where they are within their lifecycle.
How significant is your application?
Downtime of a significant application will cost you thousands of bucks in lost production and we know how crucial it is for you to get back up and operate as quickly as possible. The replacement may seem to be the easiest option, but it is always costly. VFD repair and Lenze Drive repair can save you lots of money.
Frequent Maintenance Prevent Frequent Breakdowns!
CM Industry Supply Automation recommends performance regular maintenance on industrial drives to prevent frequent breakdowns and keep them operating efficiently. Ask us about the Servo Drive Repair option that we have designed for your critical applications.
Positioning applications are often fulfilled by servo technology, but Lenze suggests that many such works can now be executed more cost-effectively, and with satisfactory performance, using the newest generation of Lenze drive or inverter drives.
Positioning is general in a wide range of machines - for instance, rotary tables, lifting, gates, conveyors, and doors. Such applications have conventionally been completed by servo drives but nowadays there are cost-effective alternatives. Particularly inverter technology is now used to attain the optimal balance between performance and saving - with Lenze referring to this procedure as Rightsizing.
The Lenze 8400 inverter drive models StateLine, HighLine, and TopLine have created new opportunities for positioning applications that need different complexity from simple to high-speed, and high-precision positioning. It offers cost savings for several machine builders.
Only where accurate top-end performance is required with the main dynamics it is essential to choose a servo drive. The 8400 StateLine is capable to handle simple positioning wherein movement takes place to a limit switch, without feedback or with feedback. 20 cycles per minute frequency can be achieved. Usual accuracies of +/-10degrees are possible without feedback.
CM Industry Supply Automation is the leading supplier of Lenze Equipment.
As an international authority in industrial automation, Lenze provides drive solutions and inclusive systems from a distinct source. As a Lenze supplier and Lenze repair service provider, we have excessive stock of Lenze products including Lenze drive, Lenze motor, Lenze gearboxes, G-Series gearboxes, and inverters. Therefore we can deliver any Lenze product on the same day at your location.
With a committed approach, we work with industrial giants to offer the best possible solution no matter whether you are looking to repair an old machine or want a new one. We can help with almost any procedure in any industry. We can even arrange for a site visit with our professionals along with a company representative if required. Our motto is to help get the right solution for your business.
Our Lenze solutions are backed by an inclusive warranty and we offer 24/7 Lenze drive Repair at all parts of India.
Get all industrial automation products sales & repair services. Call us for Lenze Drive, Keb Drive, Siemens, Allen-Bradley equipment sales and repair services.
CM Industry Supply Automation are supplier and repair services provider of drives, VFD drive (variable frequency drive), VSD (variable speed drive), inverter, frequency converter, ac drive, servo drive, servo motor, industrial drives, industrial drives and controls, industrial drives and applications, high-power servomotor, high torque DC servo motor, high-power servo drives, high frequency drives, of some well-known brands that include:
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