Gears production and manufacturing is more important than you can imagine. The gear is one of the most important mechanical elements within our daily life. Almost every technological assistant system for our needs is equipped with gears and transmission components. Nearly everybody is dependent to these in one way or another. Whether driving a car, using electric energy or using an elevator. These are only a few examples where gears are playing a major role in our day to day living. But to get a gear, a long flow of modern production technology is required, divided into several steps. This is the production chain of gears manufacturing.

The most common manufacturing chain to produce high performance gears is divided into: blank pre-machining, soft gear machining, deburring and chamfering, heat treatment and hard machining. During the first step, blank pre-machining, the turning and milling of the part occurs. During this process, the dimensions of the gear blank are defined, such as face width and tip diameter.

The next step is the soft machining of the teeth. During this step, the part gets its characteristic shape, like a gear. Important is, that during the soft machining of the teeth, a defined stock of material will be left on the flanks, which has to be removed in the last process step. During the soft machining, burrs can occur, which must be removed during the deburring and chamfering process. Furthermore, a defined chamfer can be machined along the teeth to simplify subsequent process steps.

Now, the heat treatment is required. During the heat treatment, the gear gets its required hardness. A dedicated heat treatment increases the hardness of the surface layer to a specified level and offers a softer and less rigid core of the teeth material. With this combination, a gear is able to withstand the high mechanical loads in the tooth contact and is able to absorb the bending stresses due to the dynamic loads.

As the last and one of the major steps, the hard machining of the gear is required. The hard machining removes the predetermined stock of material on the tooth flanks, defines the geometrical gear quality and is needed to improve the surface roughness.

Gear manufacturing chain Samputensili

To achieve all these process steps successfully, a deep technological know-how is needed for each step. Due to the long years’ experience, a large number of gear and transmission companies entrust Samputensili and its joint-venture StarSU with their technology in gear production. Samputensili offers a huge variety in gear cutting tools and machine tools.

For the soft machining of gears, Samputensili sells hobs, shaper cutters and Scudding® tools made from the newest cutting materials while using modern coating technologies. Combined with the highly productive deburring and chamfering system, the customers participate from the experience to decrease their production costs.

Furthermore, Samputensili produces machine tools for hard machining of gears. These are high productive and precise generating and profile grinding machines which ensure the production of the highest quality gears. With this product portfolio, Samputensili offers the market the possibility to be a technological partner along the whole production chain of gears and transmission parts. If you have any challenge in manufacturing of gears, please contact us, we have a solution for every process step in gear manufacturing.