Custom T Series Class Helical Gearboxes Manufacturers

When making T Series Class Helical Gearboxes, what key processes are used for the tooth profile processing of helical gears? How do these processes ensure the accuracy and transmission efficiency of gears? ​

Gear blank processing: laying a solid foundation​
In the manufacturing process of T series class helical gearboxes, gear blank processing is the first link and the basis for ensuring the subsequent tooth profile accuracy. As a professional gearbox and reducer manufacturer established in 1988, the company strictly implements procedures such as raw material supplier screening and review, incoming material inspection, and incoming material comparison. From global high-quality steel suppliers, alloy steel with carbon content, hardenability and other indicators that meet the requirements of high-precision gear manufacturing is selected as the raw material of the gear blank, and product quality is controlled from the source. ​
When processing the gear blank, rough machining is first performed. The CNC lathe is equipped with a servo control system with nanometer resolution, which can control the tool path with micron-level accuracy. In the rough turning process, the initial forming of the outer circle, inner hole and end face of the gear blank is completed at one time through multi-axis linkage technology, and most of the excess is efficiently removed. In the subsequent semi-finishing stage, grinding of the reference surface is particularly critical. The company uses high-precision surface grinders and slow-feed grinding technology. Through specially formulated ceramic bond grinding wheels, the flatness error of the tooth blank reference surface is controlled within a very small range under constant grinding pressure and feed speed. Its parallelism is at the industry-leading level, ensuring that the gear can be accurately clamped and positioned during subsequent tooth profile processing, reducing tooth profile deviation caused by reference error. For example, when processing the tooth blank of a large T series helical gearbox, this high-precision reference surface treatment can significantly reduce the tooth profile error of the subsequent gear hobbing process and greatly improve the processing accuracy. ​
Tooth profile cutting: shaping precise tooth profiles​
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Gear hobbing uses the development movement between the hob and the gear blank to cut the tooth profile. The five-axis linkage CNC gear hobbing machine introduced by the company is equipped with a high-precision dual servo motor drive system and a direct-drive rotary table, which can achieve a 0.001° indexing accuracy between the hob and the gear blank. The hob is shaped like a worm, and its teeth are evenly distributed on the circumference. By rotating with the gear blank at a certain transmission ratio, it gradually envelops the involute tooth shape of the gear. During the processing, the CNC system monitors and adjusts the axial movement and radial runout of the hob in real time to control the error at the micron level. At the same time, the selection and grinding of the hob are also very strict. The hob is made of high-performance powder metallurgy high-speed steel, and laser grinding technology is used. Through the five-axis linkage laser processing system, the front and rear faces of the hob are trimmed with micron-level precision to ensure the sharpness and consistency of the cutting edge, greatly reducing the roughness of the tooth surface and processing errors. ​
The gear shaping process is suitable for some occasions where gear hobbing is difficult to process, such as internal gears, duplex gears, etc. Hangzhou Hengbai Reducer's CNC gear shaping machine is equipped with a high-precision linear grating scale feedback system and a dividing mechanism directly driven by a torque motor, which can achieve high-precision motion coordination between the gear shaping cutter and the gear blank. The shape of the gear shaping cutter is similar to that of a gear. Through up and down reciprocating motion and the development motion with the gear blank, the gear shape is gradually cut out. During the gear shaping process, the equipment can automatically optimize the cutting trajectory and cutting speed of the gear shaping cutter according to the gear module, number of teeth and other parameters to ensure that the processed tooth shape meets the high-precision requirements. Whether it is gear hobbing or gear shaping, during the processing, the company will also use finite element analysis technology to simulate the force and deformation in the cutting process in advance, so as to accurately control the cutting amount, such as cutting speed, feed rate, etc., to reduce the influence of cutting force and cutting heat on the tooth shape accuracy, and ensure that the processed tooth shape meets the design requirements. ​
Tooth shape finishing: improving accuracy and performance​
In order to further improve the accuracy and transmission efficiency of the helical gear, the tooth shape is finely processed. Each fine processing process embodies the wisdom and experience of the company's professional and technical personnel. Gear shaving is one of the commonly used tooth shape finishing processes. The CNC gear shaving machine is equipped with an intelligent compensation system that can detect and correct the tooth shape error in the gear shaving process in real time. The gear shaving cutter is a high-precision tool whose tooth shape meshes with the tooth shape of the gear being processed. During the shaving process, the shaving cutter and the gear make free meshing motion without side clearance, and the extremely thin metal layer is cut off from the gear tooth surface through the tiny cutting edge on the tooth surface of the shaving cutter. In order to improve the efficiency and quality of shaving, the company has developed a special shaving process parameter optimization algorithm, which automatically adjusts the speed, feed rate and axial movement amplitude of the shaving cutter according to factors such as gear material and modulus, effectively corrects the tooth shape error, tooth direction error and reduces the tooth surface roughness. The shaving process can significantly improve the movement accuracy of the gear, and the contact accuracy is also greatly improved, making the gear more stable during the transmission process, reducing vibration and noise. ​
For helical gears with higher precision requirements, honing or grinding processes are also used. In the honing process, the CNC honing machine is equipped with an online measurement system, which can monitor the tooth surface roughness and tooth shape error in real time during the honing process. Honing is to use the high-speed relative sliding between the honing wheel and the gear to perform finishing processing on the tooth surface through the cutting action of the abrasive. The high-performance resin bond honing wheel selected by the company has uniform abrasive distribution and self-sharpening properties. It can maintain cutting ability during the honing process, further reduce the roughness of the tooth surface, improve the quality of the tooth surface, and also have a certain correction effect on the tooth shape error. ​
Gear grinding is to grind the tooth surface with a grinding wheel through a high-precision gear grinding machine. The CNC forming gear grinding machine adopts a laser interferometer positioning system and liquid hydrostatic guide technology, which can achieve nanometer-level positioning accuracy and extremely low friction resistance. During the gear grinding process, the equipment uses five-axis linkage processing technology to accurately control the shape and motion trajectory of the grinding wheel according to the three-dimensional model of the gear to grind the tooth surface. This gear grinding process can achieve extremely high tooth shape accuracy and surface quality, can effectively correct the deformation of the gear during the heat treatment process, and make the various precision indicators of the gear reach the optimal state, thereby greatly improving the transmission efficiency and service life of the T series helical gear reducer.​
Process guarantee and quality control​
Hangzhou Hengbai Reducer has a scientific management system and perfect after-sales service, and implements strict quality control in every link of helical gear tooth processing. The company has built a digital quality management system covering the entire production process, from the incoming inspection of raw materials to the process inspection of each processing procedure to the final inspection of the finished product, and each step is strictly implemented in accordance with the specifications. ​
In the raw material inspection link, in addition to the conventional chemical composition analysis and mechanical property testing, ultrasonic flaw detection and magnetic particle flaw detection technology are also used to detect defects inside the steel to ensure the quality reliability of the raw materials. During the tooth processing process, the workshop is equipped with multiple three-coordinate measuring machines and gear measurement centers. These equipment use high-precision detection systems and advanced algorithms, which can quickly and accurately detect key parameters such as tooth profile error, tooth direction error, and pitch error. Once the error is found to be beyond the allowable range, the system will automatically generate an alarm message and feed back the data to the CNC system of the processing equipment. The operator can immediately adjust the processing parameters or replace the tool to ensure that each helical gear can meet the high-precision requirements.​
At the same time, the company uses big data analysis technology to deeply mine and analyze every data in the processing process, such as cutting parameters, equipment operating status, quality inspection results, etc. By establishing a correlation model between process parameters and product quality, the processing technology is continuously optimized, potential quality problems are predicted in advance and preventive measures are taken to improve the stability and reliability of product quality. With these strict quality control measures, the T series helical gear reducers produced by Hangzhou Hengbai Reducer are not only popular in the domestic market, but also exported to more than 30 countries and regions such as the United States, Germany, the United Kingdom, and France, winning the trust of global customers with excellent and stable product quality.