What is Gear Hobbing: Benefits, Process, Applications
Gear hobbing is a type of gear machining that involves a tool to create teeth, sprockets, and splines. These are used for creating gears of different shapes and sizes used in different industries. If you need this process and want to know more about hobbing, the guide below will help you. So, read on.
What is Gear Hobbing？
Gear hobbing is a machining process that uses a cutting tool that rotates and creates the gear teeth. It is a continuous process, and the rotating speed can be adjusted as needed. The teeth can be formed on a gear blank with the cutter, and the cutter used is called a hob, which can be mounted on the CNC hobbing machine.
How Gear Hobbing Works？
A gear hobbing machine is a special type of machine that is used for performing the milling process. The speed of the gear hobbing machine is synchronized with the gear blank so that the formation of teeth is possible. The gear blank workpiece in this process is fed into the gear bank and is machined unless the required depth is achieved.
The process keeps on repeating unless all the teeth are formed completely. These hobs selections may vary based on the application, and there are different types, too. These types consist of spine, roller, spur, and chamfer.
Advantages of Gear Hobbing
There are various advantages of gear hobbing, and some of these are the following:
- The gear hobbing process is very quick compared to the other processes, and the machine is even very easy to operate.
- The process of gear hobbing is achieved using CNC machines, and hence, the accuracy remains intact. It carries out various functions in the auto mode, and the computer program creates designs. It reduces human errors.
- Gear hobbing creates versatile gears that are used for various applications, and the number of teeth can vary without any compromise on the quality.
- At one time, multiple gear blank workpieces are mounted on one arbor and are processed.
Tools and Equipment Used in Gear Hobbing
In the process of gear hobbing, there are different types of tools and equipment used, some of which are as follows:
Gear Shapers: Gear shapers are used for creating gears that have unique and internal profiles.
Gear Hobbing Machine: The gear hobbing machines offer the ability to cut gear teeth at a high speed.
Gear Milling Machines: The gear milling machines are suitable for generating and cutting the tooth profiles that are specific.
CNC Machines: The CNC machines offer automation and precision in gear manufacturing and hence offer to produce these in high volume.
Cutting Tools: There are many types of cutting tools that are used in the process of gear hobbing, like rack cutters, hobs, and broaches, which help to cut and shape the teeth.
Broaching Tools: These tools help to cut the precise shape and internal splines.
Surface Finish Tools: These finishing tools are used for finishing the gear teeth to a high quality.
Grinding Machines: Grinding machines smooth the gear teeth after being cut and shaped.
Gear Cutting vs Gear Hobbing
Gear cutting is a process that helps to create gears by removing the material using methods like broaching, shaping, and milling. It is suitable for producing gear designs that are complex and can be used with multiple materials. The process, however, is slow and is not cost-effective for high-volume production. It is commonly opted for small batch production.
Gear hobbing is also an efficient process, but it is continuous and uses a cutting tool that rotates. This cutting tool is called a hob, and it creates gears that are helical and spur types. The process of gear hobbing is suitable for large-scale production and is compatible with producing standard profiles only.
Applications of Gear Hobbing
Gear hobbing is used for many applications, and some of these are as follows:
Automobile Industry
Gear hobbing is used in the automobile industry to produce gears; these gears are used in automatic, manual, steering, and differential transmissions. They play an essential role in transmitting torque and power in cars. The process ensures that the durability and accuracy of automobile applications are attained.
Aerospace Industry
The aerospace industry uses gear hobbing for manufacturing gears used in actuation systems, landing gears, and engines of the aircraft. These gears help with precise power transmission, and they meet the quality standards regarding the safety of this industry.
Industrial Machinery
Gear hobbing is used for industrial machinery in the manufacturing industry, and compressors, tools, and pumps are used in various equipment. It creates gears that help with efficiency in power transmission. It even allows the machinery to perform its functions in a reliable and accurate way.
Robotics
The robotics industry requires gear hobbing, which helps with miniature gears. These gears are used for linear actuators, robotic joints, and motion control systems. The gears offer precise movement in robotic applications.
Challenges with Gear Hobbing
Gear hobbing is a very efficient process; however, despite its efficiency, there are some challenges encountered in the process. One of the major challenges faced in the process of gear hobbing is tool wear.
As time passes, the edges of the hob become dull, and the quality of the gear is then compromised. In order to deal with this issue, the manufacturers need to carefully assess the tool and replace it in a timely manner.
Another challenge that is observed in gear hobbing is chatter. It is the vibration during the process of hobbing that creates an uneven surface finish. It can even lead to damage to the workpiece or the hob. In order to prevent the chatter, the speed and angle during the cutting process are controlled carefully.
DEK - Outsourcing Your Gear Hobbing Project
We at DEK are the pioneers of gear hobbing and offer precise manufacturing of different gears. So, if you want to explore high-quality gear hobbing services, you can get in touch with us. We have high-tech and advanced machinery, which is operated by our highly skilled team.
Conclusion
Gear hobbing is used in various applications, and it is very important to understand the process in detail before using it in component manufacturing. The guide above features in detail the components, process, and applications, which will help you make your decision on choosing the process for your project.
