Quick Tips to Help Understand Gear Cutting

Gear Cutting

The prominence of gears in the industry has become increasingly in demand in the gear manufacturing and engineering services for over 10 years. Experienced teams of gear cutting specialist can gain a reputation as one of the leading precision engineering companies in Birmingham and the surrounding area by offering bespoke gear cutting services.

High-quality gear cutting companies provide a complete bespoke gear cutting service, meeting the highest of standards set from our track history within the industry of setting the highest quality in precision, technology and skill.

Gears suppliers provide a specialist gear cutting service having the expertise to be able to provide a high quality of standard for all types of gear cutting services they offer including:

Spurs

Bevel

Helical

Moulded

Racks

Internal gears

Gear Cutting

Gear Cutting Processes

Gear cutting is a very precise and technical process, usually having to cater to customers specific requirements so that the cut of the gear is perfect for the machinery they need it for. Commonly made from metal or plastic means there all multiple different gear cutting processes depending on the service that the customer requires.

The most common gear cutting processes used throughout the manufacturing industry are hobbing, broaching, milling and grinding. It is important to understand the difference between these various gear cutting processes so that the right technique and procedure is applied to ensure the highest quality of precision cutting meeting the customer’s specifications and requirements.

Hobbing

The hobbing gear cutting process uses a hobbing machine, these are fully automated machines cutting splines and sprockets. These hobbers come in a variety of different sizes this is because they are used to cut all types of gears from small instrument gears to large industrial machinery gears. The teeth of the gear are gradually cut into the gear through a series of cuts made by the hob.

The hobbing process for gear cutting is most commonly used for creating helical gears and spurs. This hobbing process for gear cutting is a relatively quick compared to other gear cutting processes meaning that it is commonly less expensive.

Broaching

the broaching gear cutting process is mainly used for precision machinery and cutting some of the larger gears. This process uses a toothed tool called a broach which is used to remove material when gear cutting. This process is usually used for high quantity production runs as it can be one of the more expensive compared to other gear cutting processes

Milling/Grinding

This process of gear cutting uses a rotary cutter to remove material, the milling machine covers a variety of different operations from small singular parts to big heavy-duty industrial machinery. The main difference between the milling cutter and other gear cutting processes mentioned is the cutter in the milling is moved perpendicular to its axis so the cutting edges of the tool continuously cut into and exit the gear meaning greater precision when cutting.

Open Die Forging vs Closed Die Forging

Open die forging, also called free forging, is where the billet is placed within dies which do not enclose the metal entirely. The dies used for this process are usually flat in shape although some are specially shaped for more custom projects. The opposite of this process is closed die forging where the workpiece is completely enclosed.

Open die forging is usually used for shapes such as discs, hubs, shafts, blocks, plates and other custom shapes. This type of forging process strengthens the material being used by refining the grain of the metal, this in turn also reduces porosity. Cast parts are usually not as strong or have the wear resistance of similar forged parts.

Closed die forging is the process of compressing a piece of metal in an enclosed die impression. The raw material is approximately the same size as the final forged part which is placed in the bottom die. The top die impacts on the raw material to form it into the required shape. Any sized parts can be made using this process, some of the smaller parts can be forged cold.

Brown Padlock

Most metals can be forged using this process, this includes carbon steel, alloy steels, stainless steel, tool steel, aluminium, copper and sometimes certain titanium. Magnesium requires a more specialist forging process due to it being a temperature-sensitive material. Titanium is another material which requires specialist equipment and processes for forging.

The advantages of closed die forging over open die forging are the reduce machining time due to the better surface finish, this makes it cost-effective for large production runs. If the part is simple then open die forging is better for short production runs, as there is little or no tooling cost. Machining will be required to achieve the level of accuracy required.

Depending on what you require will determine which type of process you choose. If your design is simple and only a few are needed, then open die forging is for you. On the other hand, if the shape is more complex and a larger production run is needed then closed die forging should be a consideration.

Flooring Crewe

Flooring Crewe What Flooring Solutions Are Available?

Finding the right reliable company for Flooring Crewe can be a long-winded process. Sometimes it seems to be difficult to level a floor without removing the old floor or relaying new floor, but it can be made possible through certain flooring solutions and specialist flooring Crewe companies. Two cases are discussed in this write-up to elaborate on this idea.

Flooring Crewe

Flooring Crewe Solutions – Screed or A Levelling Compound

The first idea presented for flooring Crewe solutions is a screed or levelling compound. To install engineered hardwood flooring your existing floor should be crack-free and in good shape. You should use levelling compound on the low spots of the old floor to level it before glueing wood floor on it. You should sand the upper layer of tiles to allow the glue to hold the wood flooring more effectively.

Wooden Flooring

Wood flooring Crewe: You can replace the tile floor of your kitchen laid in concrete foundation with wood flooring. Though you may not be able to use hardwood for this purpose, it can be made possible with various flooring solutions including engineered hardwood and laminate flooring with wood texture, on the existing floor. You can also use floating floor either without attaching it to the tiles or glueing it down on the tiles of the old floor.

Types of Tiles

Ceramic tile flooring Crewe: It can be one of the good flooring ideas for your existing vinyl floor if it is glued firmly on a concrete base. You only must scrub the floor to remove grease and dirt from it before applying a thin layer of mortar and tile on it.

But if the subfloor under vinyl tiles is of wood then first you will have to install a cement backer board of” thickness over the joints of the floor with corrosion-free screws before laying tiles.

Ceramic tiles can also be laid directly on the existing vinyl floor if it is perfectly levelled by an expert flooring Crewe company. But you will have to clean vinyl tiles for better adherence of the mortar. It is better to hire a professional to do the job.