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.
    Material Procurement
  • Rough Cutting
    Selection of material (round bars). Diameter and length are cut larger than the outer diameter and length of the finished product.
    Rough Cutting
  • Lathe Operations
    Perform rough machining to create the basic form (gear blank) by a lathe.
    Lathe Operations
  • Gear Cutting
    Generate gear teeth by our gear-cutting machines. After cutting, gear teeth will have imperfections.
    Gear Cutting
  • Burr Removal
    Remove all imperfections (burrs), chamfer the sharp corners for safety in use and to prevent fracturing.
    Burr Removal
  • Black Oxide Coating
    Apply black oxide coating, as a surface treatment, to prevent rusting residue and texturing.
    Black Oxide Coating
  • 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.
    Rack Material Procurement
  • Gear Cutting
    Generate gear teeth by our gear-cutting machines. After cutting, gear teeth will have imperfections.
    Gear Rack Cutting
  • Removal of Burrs
    Remove all imperfections (burrs), chamfer the sharp corners for safety in use and to prevent fracturing.
    Removal of Burrs
  • Press Operations
    Apply press operations to correct warpage that occurred in the gear-cutting processes.
    Rack Press Operations
  • End Machining
    For use of racks in contact, end machining is applied to align the ends, based on tooth space.
    Rack End Machining
  • Boring
    For mounting , boring of counterbores is applied by center machining.
    Rack Boring
  • Black Oxide Coating
    Apply black oxide coating, as a surface treatment, to prevent rusting residue and texturing.
    Rack Black Oxide Coating
  • 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.
    Bevel Gear Material Procurement
  • Rough Cutting
    Selection of material (round bars). Diameter and length are cut larger than the outer diameter and length of the finished product.
    Rough Cutting
  • Lathe Operations
    Machine to create basic form (gear blank) by turning.
    Bevel Gear Lathe Operations
  • Gear Cutting
    Generate gear teeth by our gear-cutting machines. After cutting, gear teeth will have imperfections.
    Bevel Gear Cutting
  • Burr Removal
    Remove all imperfections (burrs), chamfer the sharp corners for safety in use and to prevent fracturing.
    Bevel Gear Burr Removal
  • Black Oxide Coating
    Apply black oxide coating, as a surface treatment, to prevent rusting residue and texturing.
    Bevel Gear Black Oxide Coating
  • 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.
    Worm Material Procurement
  • Rough Cutting
    Selection of material (round bars). Diameter and length are cut larger than the outer diameter and length of the finished product.
    Worm Rough Cutting
  • Lathe Operations
    Perform rough machining to create the basic form (gear blank) by turning.
    Worm Lathe Operations
  • Gear Cutting
    Generate gear teeth by our gear-cutting machines. After cutting, gear teeth will have imperfections.
    Worm Gear Cutting
  • Burr Removal
    Remove all imperfections (burrs), chamfer the sharp corners for safety in use and to prevent fracturing.
    Worm Burr Removal
  • Black Oxide Coating
    Apply black oxide coating, as a surface treatment, to prevent rusting residue and texturing.
    Worm Black Oxide Coating
  • 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