MANUFACTURING OF GEARS

• Spur Gears
• Worm Gear
• Bevel Gears
• Gear Rack
• Helical Gears
• Miter Gears
• Plastic Gears
• Screw Gears
• Internal Gears
• Bevel Gearbox
• Other Products

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• The ABC's of Gears - B
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• Manufacturing of Gears

9. Manufacturing of Gears / KHK stock gears are produced by the following manufacturing processes.

For gear manufacturing, there are several fabrication approaches. However, we will show you how KHK Stock Gears are produced by introducing our typical cutting processes, selection of materials and the packaging of our gears.

9-1 Manufacturing Process of Spur Gears

Shown is a typical manufacturing process for the production of SS-type of KHK Spur Gears.
(Some photographs may not be of the SS-type of gears, and shown as examples)

• Material Procurement
  Source the material: S45C Round Bars, KHK always have plenty in stock.
  
• Rough Cutting
  Selection of material (round bars). Diameter and length are cut larger than the outer diameter and length of the finished product.
  
• Lathe Operations
  Perform rough machining to create the basic form (gear blank) by a lathe.
  
• Gear Cutting
  Generate gear teeth by our gear-cutting machines. After cutting, gear teeth will have imperfections.
  
• Burr Removal
  Remove all imperfections (burrs), chamfer the sharp corners for safety in use and to prevent fracturing.
  
• Black Oxide Coating
  Apply black oxide coating, as a surface treatment, to prevent rusting residue and texturing.
  
• Packing
  Package each product and place a printed label stating the product’s name.

9-2 Manufacturing Process of Racks

Shown is a typical manufacturing process for the production of SRFD-type of KHK Racks.
(Some photographs may not be of the SRFD-type of gears, and shown as examples)

• Material Procurement
  Source the material: S45C Square Bars. KHK always have plenty in stock.
  
• Gear Cutting
  Generate gear teeth by our gear-cutting machines. After cutting, gear teeth will have imperfections.
  
• Removal of Burrs
  Remove all imperfections (burrs), chamfer the sharp corners for safety in use and to prevent fracturing.
  
• Press Operations
  Apply press operations to correct warpage that occurred in the gear-cutting processes.
  
• End Machining
  For use of racks in contact, end machining is applied to align the ends, based on tooth space.
  
• Boring
  For mounting , boring of counterbores is applied by center machining.
  
• Black Oxide Coating
  Apply black oxide coating, as a surface treatment, to prevent rusting residue and texturing.
  
• Packing
  Package each product and place a printed label stating the product’s name.

9-3 Manufacturing Process of Bevel Gears

This is a typical manufacturing process for SM-type of KHK Bevel Gears.
(Some photographs may not be of the SM-type of gears, and shown as examples)

• Material Procurement
  Source the material: S45C Round bars, KHK always have plenty in stock.
  
• Rough Cutting
  Selection of material (round bars). Diameter and length are cut larger than the outer diameter and length of the finished product.
  
• Lathe Operations
  Machine to create basic form (gear blank) by turning.
  
• Gear Cutting
  Generate gear teeth by our gear-cutting machines. After cutting, gear teeth will have imperfections.
  
• Burr Removal
  Remove all imperfections (burrs), chamfer the sharp corners for safety in use and to prevent fracturing.
  
• Black Oxide Coating
  Apply black oxide coating, as a surface treatment, to prevent rusting residue and texturing.
  
• Packing
  Package each product and place a printed label stating the product’s name

9-4 Manufacturing Process of Worm Gears

This is a typical manufacturing process for SW-type of KHK Worm Gears.
(Some photographs may not be of the SW-type of gears, and shown as examples)

• Material Procurement
  Source the material: S45C Round bars, KHK always have plenty in stock.
  
• Rough Cutting
  Selection of material (round bars). Diameter and length are cut larger than the outer diameter and length of the finished product.
  
• Lathe Operations
  Perform rough machining to create the basic form (gear blank) by turning.
  
• Gear Cutting
  Generate gear teeth by our gear-cutting machines. After cutting, gear teeth will have imperfections.
  
• Burr Removal
  Remove all imperfections (burrs), chamfer the sharp corners for safety in use and to prevent fracturing.
  
• Black Oxide Coating
  Apply black oxide coating, as a surface treatment, to prevent rusting residue and texturing.
  
• Packing
  Package each product and place a printed label stating the product’s name.

Related links :
Gear manufacturing – Main page of gear manufacturing
Production Processes of Spur Gear – A part of Introduction to Gears
Production Processes of Gear Rack – A part of Introduction to Gears
Production Processes of Bevel Gear – A part of Introduction to Gears
Gear Production Facilities – A part of Introduction to Gears