Gear Manufacturing Process

　　Due to the demands on precision, gear production is quite complex. Today, gear manufacturing is an industry unto itself, relying on a variety of processes, both traditional and modern, to ensure the proper balance between cost, quality, and operations.

　　Casting is a simpler process mainly used to prepare blanks or cylinders for gears, while gear teeth are produced by machining. However, due to its mass-producibility and relative ease, it is a viable integral gear manufacturing process for many applications. However, there is one area where casting is the most popular manufacturing method in the industry. That is producing very large gears. In the case of large diameters, machining methods and other gear-forming methods are less feasible. In general, the larger gears are almost always the spur gear type. Therefore, their relative simplicity makes casting a good choice. Among the most common types of casting methods, shell casting, die casting, sand casting, and metal casting are the most common in gear production. Other methods have limited use in some applications.

　　Extrusion and cold drawing are other versatile and simple gear-forming process. The fact that extrusion has a lower tooling outlay doesn't mean it's the most economical process. Extrusion, as the name implies, is the process of passing a heated metal profile through a smaller predetermined shape. As a result, you will have a rod of the desired shape with a hardened and smooth outer surface. The cold drawing process is very similar to extrusion. There are two differences. Extrusion pushes the blank through the die pulling it. Another difference is temperature. Cold drawing does not heat the billet. Thereby improving mechanical properties at the expense of cost.

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