All machines from the category Gear manufacturing

How a gear cutting machine works

A gear cutting machine is a highly specialised machine tool for the production of gear profiles. It is used in mechanical production to manufacture gears for gearboxes, drives and machines precisely and economically. Depending on the area of application and production technology, a distinction is made between gear hobbing machines, gear shaping machines, gear grinding machines and gear skiving machines, see below. The production goal of gear manufacturing for each technology is to produce an exact tooth profile with a high surface quality and dimensional accuracy.

Types of gear cutting machines

Depending on the production technology used to manufacture gears, we differentiate between the following gear cutting machines:

• Gear hobbing machine
• Gear skiving machine (power skiving)
• Gear grinding machine
• Gear shaping machine

Gear manufacturing process

Gear manufacturing begins with clamping the workpiece, such as a blank, on a rotating workpiece table. At the same time, the cutting tool, e.g. a hob cutter, is brought into position. During hobbing, the tool rotates in synchronisation with the rotation of the workpiece - a so-called hobbing motion is created. Tooth by tooth is continuously machined out of the workpiece. The hobbing tool reproduces the shape of the tooth space. In gear shaping, on the other hand, an oscillating tool works linearly into the material while the workpiece continues to rotate step by step.

For maximum precision in gear production, gear grinding machines are used, which refine the tooth profile by grinding after milling or hardening. This ensures high dimensional accuracy and surface quality, as required in the automotive or aerospace industries, for example.

Modern gear cutting machines are CNC-controlled and enable a high degree of repeat accuracy and flexibility in production through precise programming. They are a central component of gear manufacturing in industrial production - wherever friction-locked movements with an exact transmission ratio are required.

How does profile milling work?

Profile milling basically belongs to the group of gear cutting processes, but in contrast to generating gear hobbing, it is classified as a shape-forming process. It is primarily used when special profiles, individual tooth machining or small series have to be produced where a generative process such as hobbing or gear shaping is not technically or economically feasible.

• The milling tool has exactly the profile that is to be introduced into the workpiece.
• Each tooth is milled individually, often by indexing the workpiece after each tooth.
• There is no rolling motion - it is therefore not a generating process.
• Suitable for special gears, prototypes, repairs or internal gears with complex geometries.
• Tool example: form milling cutter, disc milling cutter or face milling cutter with profile contour.

What is the enveloping cut in gear manufacturing?

The enveloping cut is a central concept in gear cutting technology - especially in generating processes such as hobbing, gear shaping or power skiving. The workpiece profile - e.g. the tooth flank of a gear - is created by superimposing many cutting movements of the tool. These cuts "encase" the resulting profile, similar to a shell, and create it indirectly through movement, not through a statically transferable tool profile.

A simple example is hobbing:

• The hob cutter has a relatively simple tool profile (e.g. straight teeth) that does not correspond to the subsequent tooth profile.
• The synchronised movement of milling cutter rotation and workpiece rotation causes the tool to roll over the workpiece.
• The cutting edges of the milling cutter cut off material in many small steps - the sum of these tracks results in the exact tooth profile.
• This "result of the movement" is the envelope cut.

Features of the envelope cutting process:

• The workpiece profile is created from the kinematic movement, not from a predefined tool profile.
• Generating processes are based on the enveloping cut (e.g. hobbing, gear shaping, power skiving).
• Non-generating processes such as profile milling generate the tooth profile directly - without an envelope cut.

Advantages of the envelope cut:

• High accuracy and repeatability
• Standardised tools can be used for many different gears
• Efficient series production thanks to continuous machining

Applications in industrial production

Gear cutting machines are indispensable in industries where precise gear components are required. They are used particularly frequently in mechanical engineering, the automotive industry, toolmaking, aerospace, rail vehicle construction, the wind energy sector, medical technology, robotics, conveyor technology and shipbuilding.

Typical workpieces that are manufactured on a gear cutting machine are

• Spur gears
• bevel gears
• worm gears
• Internal gears
• gear racks
• Planetary gears
• Ring gears for planetary gears
• Synchroniser rings
• Gear shafts
• Gears for steering systems

These components can be found in gearboxes, drives and complex machine components. They must fulfil the highest requirements in terms of accuracy of fit, smooth running and load capacity. Gear cutting machines enable precisely these qualities. Gear manufacturing is automated, efficient and adapted to a wide range of materials such as steel, aluminium or plastic.

Gear cutting machine tools

Highly specialised tools are used in gear cutting machines, depending on the machining process and gear geometry. The most important tool types include

• Hob cutters - for the economical milling of external and internal gears
• Gear shaping wheels - for shaping internal gears with high dimensional accuracy
• Grinding wheels - for gear grinding on hardened gears
• Mould cutters - for special profile gears
• Honing wheels - for fine machining and optimisation of the tooth flank geometry
• Disc cutters - for milling individual tooth spaces on smaller or more complex components
• Module milling cutters - standardised milling tools for gears with a defined module
• Broaching tools (broaches) - for the precise broaching of internal gears in a single stroke movement
• Power skiving tools - modern tools for highly dynamic skiving of internal and external gears
• Diamond or CBN-tipped grinding tools - for hard fine grinding of high-strength gears with maximum surface quality
• Profile rollers - for shaping during cold forming (e.g. in the manufacture of gears using profile rollers)
• Shaping tools - for simpler shaping processes, especially for prototypes or customised products
• Deburring tools - for reworking and removing burrs from tooth flanks
• Workpiece clamping devices with integrated centring - technically speaking, these are auxiliary tools, but are essential for high machining accuracy

A face milling cutter is not a standard tool for industrial series gearing, but is used, for example, in the manufacturer of special gears or internal gears if a hobbing cutter cannot be used.

Accessories for a gear cutting machine

Central components are clamping devices such as three-jaw chucks, centring clamping systems or customised clamping fixtures to hold workpieces securely and accurately in position. Equally important are tool holders that precisely guide hobs, shaping tools or grinding wheels. Coolants and lubricants that improve heat dissipation, reduce tool wear and improve surface quality are part of the machining process.

Measuring technology such as gear gauges, coordinate measuring machines or tactile sensors ensure precise control of the tooth geometry. Other important equipment includes filter systems, chip conveyors and extraction systems to ensure machine cleanliness and process reliability. Programming workstations and interface modules for data exchange are also essential in CNC production.

Leading manufacturers of gear cutting machines

In our manufacturers directory you will find companies that produce gear cutting machines for metalworking.

The following terms are frequently searched for: Affolter gear cutting machine, Burri gear cutting machine, DVS gear cutting machine, EMAG gear cutting machine, Gleason gear cutting machine, Höfler gear cutting machine, KAPP gear cutting machine, Klingelnberg gear cutting machine, KOEPFER gear cutting machine, Liebherr-Verzahntechnik gear cutting machine, Monnier + Zahner gear cutting machine, Pittler gear cutting machine, Präwema gear cutting machine, Profilator gear cutting machine, Profiroll gear cutting machine, Reishauer gear cutting machine

Choosing the right gear cutting machine

If you want to buy a gear cutting machine, there are several important features and specifications to consider.

• A key criterion is the traverse path and machining area, which determine the maximum workpiece size that can be machined.
• The tool interface is equally important, as it enables the use of different gear cutting tools.
• Pay attention to the machine accuracy, in particular concentricity, indexing accuracy and positioning accuracy.
• Control technology plays a key role - modern Controls offer high flexibility, automation options and intuitive user interfaces.
• Automation functions such as workpiece changers or robot connection are advantageous for series production.
• Other important features include spindle power, cutting speed and the option of dry or wet machining.
• Last but not least, you should pay attention to service availability, spare parts supply and the possibility of software customisation to ensure long-term investment security.

Find the gear cutting machine that suits your production requirements now at maschinenauswahl.de.