1. Machining

Machining is a precise and versatile process that uses cutting tools to shape gears from a solid workpiece. It offers exceptional accuracy, tight tolerances, and the ability to create complex gear profiles. This makes it a popular choice in gear manufacturing.

2. Casting

Casting is a versatile manufacturing method that involves pouring molten metal into a mould to create gears. It offers the ability to produce complex gear shapes and is suitable for large-scale and small-scale production. Gear casting provides good dimensional accuracy and can utilize various materials.

3. Hobbing

Hobbing is a specialized machining process that uses a cutting tool called a hob to generate gear teeth. The hob is gradually fed into the workpiece, producing precise and uniform gear teeth. Hobbing is widely used for the high-volume production of gears and ensures excellent surface finish and tooth accuracy.

5. Broaching

Broaching is a highly efficient process for producing gears with irregular profiles or large tooth counts. It involves using a toothed cutting tool called a broach to remove material in a series of linear passes. Broaching offers rapid and accurate gear production, making it suitable for a wide range of applications.

Machining is a precise and versatile process that uses cutting tools to shape gears from a solid workpiece. It offers exceptional accuracy, tight tolerances, and the ability to create complex gear profiles. This makes it a popular choice in gear manufacturing.

Machining is a precise and versatile process that uses cutting tools to shape gears from a solid workpiece. It offers exceptional accuracy, tight tolerances, and the ability to create complex gear profiles. This makes it a popular choice in gear manufacturing.

7. Blanking

Blanking is a shearing process that cuts out gear shapes from flat metal sheets or strips. It is a cost-effective method for producing gears with simple designs and high volumes. Blanked gears can be further processed through machining or other finishing techniques to achieve the desired specifications.

8. Forging

Forging is a shaping process involving heating, hammering, or pressing metal to form gears. It produces gears with excellent strength, enhanced mechanical properties, and improved fatigue resistance. Forged gears are commonly used in heavy-duty applications that require exceptional durability and reliability.

4. Injection Molding

Injection moulding is a process where molten plastic or polymer material is injected into a mould cavity to create gears. It is commonly used for producing plastic gears with intricate designs and high volumes. Injection-moulded gears offer excellent design flexibility and cost-effectiveness and can be tailored for specific applications.

9. Die Casting

Die casting is a process that utilizes molten metal injected into a die cavity under high pressure to create gears. It offers excellent dimensional accuracy, surface finish, and high production rates. Die-cast gears are widely used in automotive and consumer electronics industries, requiring lightweight and intricate designs.

10. Form Milling

Form milling is a gear manufacturing process that involves using a special cutter to create gear profiles. The cutter follows the contour of a template or master gear, producing gears with precise tooth profiles. Form milling is commonly used for small-batch production or prototyping, offering flexibility and accuracy in gear manufacturing.