Gear transmission is one of the most widely used mechanical systems in modern machinery and serves as a fundamental component in mechanical products. Compared to other transmission methods such as belt drives, chain drives, or hydraulic systems, gear transmission offers a wide power range, high efficiency, precise motion transfer, and long service life. This makes it an essential part of many mechanical systems and the most common form of transmission in machines. Gears have played a crucial role in industrial development and are often seen as a symbol of industrial progress. Therefore, understanding the latest processing technologies and future trends in gear manufacturing is of great importance.
**1. Recent Advances in Gear Manufacturing Technology**
The general gear manufacturing process involves five main stages: material preparation, blank machining, cutting, tooth surface heat treatment, and finishing. Among these, heat treatment and finishing are critical steps that determine the quality and performance of the gear. Globally, efforts are being made to enhance gear manufacturing by improving both the technology and the equipment used in the process.
**2. Hard Hobbing Technology**
Traditionally, hard tooth surfaces required grinding, which was inefficient, especially for large gears with big modules. Hard hobbing, also known as tooth scraping, uses a special hard alloy hob to machine the gear after carburizing and quenching, achieving a precision level of 7. This method can handle various helix angles and module sizes from 1 to 40 mm. For standard hardened gears, the "rolling-heat treatment-scraping" process is commonly used, allowing both rough and finish machining on the same machine. For higher surface quality, additional scraping may be applied. High-precision gears typically follow a "rolling-heat treatment-scraping-grinding" process, where scraping replaces coarse grinding, reducing heat treatment deformation and saving significant grinding time. This approach is particularly useful for large modulus and diameter gears, as no suitable grinding machines exist for them.
Cooling is essential during hard hobbing to prevent tool wear and damage. A metalworking fluid is used to cool the tool and workpiece while removing chips, extending tool life and improving surface finish. Special oil-based cutting fluids, like KR-C20 gear oil, are often used due to their excellent cooling, cleaning, and lubrication properties.
**3. Dry Cutting Technology**
Dry cutting involves machining without the use of cooling or lubricating oils. It relies on high-speed cutting to minimize contact between the tool and the workpiece, and compressed air or similar methods to remove chips and control temperature. Properly set cutting parameters can allow 80% of the heat to be carried away by the chips. To further improve tool life and workpiece quality, a small amount of lubricant (10–1000 ml/hour) can be applied. The resulting chips are dry, and micro-lubrication does not negatively affect the workpiece’s accuracy, surface quality, or internal stress. Automated monitoring systems can also be used to control the process effectively.
**4. Chipless Machining of Gears**
Unlike traditional methods like hobbing, shaping, or grinding, chipless machining uses plastic deformation or powder sintering to form or improve the gear teeth. This method includes cold forming at room temperature or hot forming at around 1000°C. Cold forming techniques include cold rolling and forging, while hot forming includes hot rolling, precision die forging, and powder metallurgy. These methods increase material utilization from 40–50% in cutting processes to 80–95%, significantly boosting productivity. However, due to mold strength limitations, this technique is mainly suitable for small module gears. For high-precision applications, final finishing using chip removal is still necessary.
**5. Development of Gear Processing Lubrication Technology**
In recent years, environmental and resource pressures have led to the emergence of new green cutting technologies, such as dry cutting, micro-lubrication, and low-temperature cold-air cutting. These alternatives to traditional lubrication methods have advanced cutting technology and introduced new demands on machine tools, tool materials, and lubricants. As a result, the industry continues to evolve toward more sustainable and efficient solutions.
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