Detailed Explanation of Gear Processing Methods - Forming Method

Definition of Gear Processing Forming Method: The forming method, also known as the shaping method, refers to the use of shaping tools with tooth profiles matching those of the gear to cut the tooth surfaces. This includes methods such as gear milling, gear hobbing, and gear shaping. The following content will introduce the gear processing forming method:

Advantages:

- Simple processing equipment with low tool costs.

Disadvantages:

1. Approximate tooth profile with low processing accuracy.

2. After each tooth slot is processed, the workpiece needs periodic indexing, resulting in low productivity.

3. Different forming tools are required for gears with the same module but different tooth numbers and tooth profile shapes.

4. The forming method is divided into two main categories: hobbing method/milling method.

Hobbing Method Principle:

Using the involute (helical) gear as the shaping method, the machine tool does not require surface forming motion, forming a tangent method using the guideline (straight line). The machine tool requires two forming motions: the rotation of the hob and the axial movement of the hob along the gear blank. After milling one tooth, the hob returns to its original position, and after the workpiece is indexed, the next tooth slot is milled until all teeth are machined.

Applications:

1. Repair and maintenance industry (single-piece, small batch production).

2. Processing gears using single-tooth profile shaping tools.

3. Heavy machinery manufacturing industry, addressing the lack of large gear processing machine tools.

Milling Method Principle:

When using multi-tooth profile shaping tools, all tooth slots can be machined in one working cycle, resulting in high productivity but complex tool manufacturing.

Applications:

Only suitable for mass production.

In summary, the forming method produces gears with low accuracy and is a relatively traditional gear processing approach. As the gear industry advances towards precision products, the use of the forming method is expected to decrease, making way for more modern techniques.