Techniques for Rust Prevention in Gear Processing: How to Extend the Lifespan of Gears?

2023-04-03

Gears, as important components of mechanical transmission, often operate in environments with high temperatures, high pressures, high speeds, and heavy loads. To ensure the lifespan and reliability of gears, rust prevention treatment is necessary. This article summarizes the following suggestions based on research into rust prevention techniques for gear processing, to help readers better protect gears and extend their service life. 1. Choose Suitable Materials The choice of material for gears has a decisive impact on rust prevention treatment. Common gear materials on the market include steel, copper, cast iron, and aluminum alloys. Steel is a commonly used material for manufacturing gears, known for its high strength and good fatigue resistance, but it is also prone to rust. Therefore, when choosing steel as the gear material, it is important to consider using appropriate rust-proof coatings for corrosion protection. Copper and cast iron materials generally have better corrosion resistance compared to steel, so they usually do not require rust prevention treatment. Additionally, aluminum alloy gears do not need extra rust prevention treatment due to their inherent rust resistance. 2. Perform Surface Treatment The surface of the gear is easily damaged during operation. Therefore, appropriate surface treatment during processing can not only improve the surface quality of the gear but also enhance its corrosion resistance. Common surface treatment methods include chrome plating, electro-galvanizing, hot-dip galvanizing, and phosphating. 3. Use Appropriate Rust-Proof Coatings Rust-proof coatings are an effective means to enhance the rust and corrosion resistance of gears. Currently, widely used types of rust-proof coatings on the market include organic coatings, inorganic coatings, and coating composites. Among these, inorganic coatings are the most widely used because they can effectively prevent rust without damaging the performance of the gear itself. 4. Properly Control the Working Environment When using gears, it is advisable to avoid exposing them to high temperatures, high humidity, dusty, and corrosive gas environments, as these can accelerate rusting. Some common working environment impacts on gears are as follows: (1) High-temperature environment: This can lead to oxidation of the gear surface, reduced hardness, and accelerated wear of the tooth surface, so it is best to avoid excessive temperatures when using gears. (2) Humid environment: This can cause moisture to accumulate on the gear surface, and in a file bag environment, it can lead to rusting of the gear surface, so it is important to ensure that the storage environment for gears is dry. (3) Dusty environment: Dust can enter the interior of the gear, damaging the surface and tooth surface, so the time gears spend working in dusty environments should be minimized. (4) Corrosive gas environment: Environments with acid mist, alkaline mist, etc., can corrode the surface and tooth surface of the gear, causing damage. 5. Conduct Regular Inspections During use, gears will inevitably encounter some issues. Therefore, regularly checking the wear condition of the gears and repairing them in a timely manner can effectively extend their service life. Regular inspections of gears mainly include the following aspects: (1) The condition of corrosion and rust on the gear surface; (2) The wear condition of the gear teeth; (3) The quantity and quality of the gear lubrication oil; (4) The coordination of gear transmission: Good coordination among the gears in transmission is essential; otherwise, it can lead to increased wear of the tooth surfaces. The content of this article is sourced from the internet. If there are any issues, please contact me for removal!

What is pitch in gear processing? How to calculate the pitch of a gear?

2023-03-17

The pitch of a gear refers to the center distance between adjacent tooth slots on the gear. Pitch is an important parameter that helps determine the geometric shape and transmission ratio of the gear. Correct calculation of pitch ensures the normal operation and accurate transmission of the gear. The calculation of pitch requires parameters such as the gear's modulus (or nominal diameter), number of teeth, and type of gear. Below are the general steps for calculating pitch. First, it is necessary to determine the starting point for the pitch calculation. For gears, the starting point is generally the center of the gear. Then, the pitch can be calculated based on the gear's modulus and number of teeth. The pitch of the gear can be calculated using the following formula: Pitch (P) = π * Modulus (m) Where π is a constant, approximately equal to 3.14159. The modulus is a parameter that measures the size of the gear tooth slots, usually used to represent the width of the tooth slot. The modulus can be calculated based on the gear's nominal diameter (D) and number of teeth (z) using the formula: Modulus (m) = Nominal Diameter (D) / Number of Teeth (z) The nominal diameter is the diameter of the gear, which is one of the design parameters of the gear. The number of teeth is the number of tooth slots on the gear, which is also one of the design parameters. The pitch of the gear can also be calculated using the diameter of the gear. The diameter of the gear can be calculated using the following formula: Nominal Diameter (D) = Modulus (m) * Number of Teeth (z) Based on the nominal diameter and number of teeth, the modulus of the gear can be obtained, and thus the pitch can be calculated. In actual gear processing, it is also necessary to consider the correction of pitch. During the gear processing, due to processing errors and measurement errors, the pitch often has a certain deviation. To ensure the precision and accuracy of the gear, corrections need to be made when calculating the pitch. The corrected pitch can be calculated using the following formula: Corrected Pitch (Pc) = Pitch (P) + Correction Factor (C) Where the correction factor is obtained from actual measurements. By adjusting the correction factor, the error in pitch can be effectively corrected. The calculation of pitch is very important for the design and processing of gears. Accurate pitch can ensure the transmission efficiency and operational stability of the gear. In actual gear processing, it is necessary to fully consider the calculation and correction of pitch to ensure the quality and performance of the gear. The content of this article is sourced from the internet. If there are any issues, please contact me for deletion!

What role does cutting fluid play in gear machining?

2023-02-13

Gear processing refers to the process of machining raw materials into gears through processes such as cutting, grinding, rolling, and forging. During the gear processing, cutting fluids are widely used in cutting operations, serving multiple functions such as cooling, lubrication, cleaning, rust prevention, and chip removal. Below, we will detail the role of cutting fluids in the gear processing process. Firstly, cutting fluids play a cooling role in gear processing. During the gear processing, due to the high-speed load cutting action, a large amount of frictional heat is generated, causing the temperature of the tool, workpiece, and fixture to rise. If not cooled in time, it can lead to deformation of parts or accelerated tool wear. The cooling performance of cutting fluids effectively reduces the working temperature by absorbing and carrying away frictional heat, slowing down thermal deformation of the tool and workpiece, and improving the precision and quality of the cutting process. Secondly, cutting fluids serve a lubrication role in gear processing. During the gear processing, friction occurs between the tool and the workpiece. Without the presence of a lubricant, the friction coefficient increases, leading to greater mechanical energy loss and reduced cutting efficiency. Cutting fluids effectively reduce the contact friction between the tool and the workpiece surface, lower the friction coefficient, and decrease wear and heat generation, thereby reducing the tool wear rate and extending tool life. Thirdly, cutting fluids play a cleaning role in gear processing. During the gear processing, impurities such as metal chips, oil sludge, and sand particles are generated. If not removed in time, they can affect the quality and effectiveness of the cutting. Cutting fluids have good cleaning properties, quickly washing the cutting area and carrying away metal chips and impurities, keeping the cutting area clean and preventing clogging and accumulation. Fourthly, cutting fluids serve a rust prevention role in gear processing. Due to their lubricating and cooling properties, cutting fluids can protect the surfaces of tools and workpieces, preventing oxidation and corrosion, thus extending the service life of tools and workpieces and improving processing quality. This is especially important for materials that are prone to rust, such as low-carbon steel and stainless steel. Using cutting fluids during processing can effectively prevent the formation of oxides on the material surface, reducing adverse processing phenomena caused by the accumulation of oxidation products. Finally, cutting fluids play a chip removal role in gear processing. In the gear cutting process, chips are an unavoidable byproduct. If chips are not removed from the processing area in time, they can clog the gaps between the tool and the workpiece, affecting the cutting effect. Cutting fluids can wash away the chips, keeping the processing area clean, reducing frictional resistance during the cutting process, and improving processing efficiency and quality. The content of this article is sourced from the internet. If there are any issues, please contact me for deletion!

What are the advantages of using umbrella gears? In which fields are they applied?

2023-01-17

1. First, let's introduce the classification of bevel gears. Bevel gears are a type of gear. Gears have many different classifications, and different regions have different names for them, so it is essential for people to understand the classification of products to comprehend the parts. Spiral bevel gears are one of these types. In some places, they are referred to as arc bevel gears, while in others, they are called conical bevel gears. 2. Advantages of bevel gears During use, bevel gears have a very high transmission efficiency, and their transmission performance is very stable. These components overlap with a large overlap ratio, which gives them a very high load-bearing capacity, resulting in smoother transmission. The production and processing of bevel gears can also save raw materials, and they have advantages such as wear resistance, long service life, and low noise during use. 3. Bevel gears are widely used in various machine tools Bevel gears are widely used in various machine tools, such as mining, shipping, aerospace, and other equipment, making their application range very broad.

Arc gear

2022-12-23

Arc gears, with a normal working tooth profile that is an arc, are helical cylindrical gears. When two arc gears mesh, the contact between the teeth is point contact. Their load-carrying capacity is greater than that of involute gears of the same specifications, and they have high transmission efficiency with minimal tooth surface wear. They are suitable for low-speed heavy loads or high-speed high-power transmission.

Basic knowledge required for gear design.

2022-11-09

In mechanical design, the design of gears as mechanical elements requires essential technical knowledge. This is true even if you choose to use pre-designed gears. The knowledge of gears that needs to be mastered includes various calculation formulas used for gear strength and size calculations, types of gears, specialized terminology related to gears, gear pair speed ratios and directions of rotation, tooth profiles and tooth thickness, backlash, ISO and AGMA standards related to precision levels, assembly accuracy of gears, gear materials and heat treatment, hardness of gears, lubrication issues when using gears, strategies for noise and damage problems, geometric tolerances used in gear drawing, and special geometric symbols used in mechanical drafting.

The working principle of a bevel gear is based on the transmission of rotational motion between shafts that are typically at right angles to each other. Bevel gears have conical shapes, allowing them to mesh smoothly. When one bevel gear is rotated, its teeth engage with the teeth of another bevel gear, transferring motion and torque from one shaft to the other. This design allows for changes in the direction of the drive, making bevel gears essential in various mechanical systems, such as in differentials in vehicles.

2022-10-13

1. Working Principle of Straight Bevel Gears According to the design of bevel gears, they are divided into straight and spiral teeth. The design, manufacturing, and installation of straight bevel gears are relatively simple. However, a downside is that they produce more noise. They can be used in low-speed machines. During operation, their transmission runs stably and they are widely applied. 2. Working Principle of Spiral Bevel Gears Unlike straight bevel gears, the design of spiral bevel gears is more complex. However, their advantage is that the entire transmission runs smoothly. Compared to straight bevel gears, they produce much less noise and have a greater load capacity, making them suitable for high-speed heavy-load applications. The transmission power is greater than that of straight bevel gears. 3. Installation of Bevel Gears During the installation of bevel gears, the center lines of the two shafts should first be adjusted to the same plane to facilitate installation. Then, adjust the gear clearance. After that, adjust the shaft runout. Use a special feeler gauge to check. A slight deviation is acceptable. If the deviation is too large, the installation of the bevel gears will fail. Check for any unusual noises when the gears rotate. Choosing the right gears can achieve twice the result with half the effort in mechanical operations. As a common transmission mechanical component, there are many types of gears, among which bevel gears need to be carefully checked after installation.

Gear Processing Technology: Selection of Gear Processing Reference

2022-09-08

The gear processing technology often varies in the selection of processing references due to the different structural shapes of gears. For shaft gears, positioning is mainly done using the vertex hole; for hollow shafts, after drilling the central inner hole, positioning is done using the inclined surfaces of the holes at both ends; when the hole diameter is large, a cone plug is used. Vertex positioning has high precision and can achieve reference coincidence and unification. For hole gears, the following two positioning and clamping methods are commonly used during tooth surface processing. 1. Positioning by inner hole and end face This positioning method uses the inner hole of the workpiece to determine the positioning location, and the end face serves as the axial positioning reference, with clamping against the end face. This allows the positioning reference, design reference, assembly reference, and measurement reference to coincide, resulting in high positioning accuracy, making it suitable for mass production. However, it requires high manufacturing precision for the fixture. 2. Positioning by outer circle and end face When the fit clearance between the workpiece and the machining center shaft is relatively large, a dial gauge is used to correct the outer circle to determine the center position, and the end face is used for axial positioning, with clamping from the other end face. This positioning method requires calibration for each workpiece, resulting in lower productivity; at the same time, it has high requirements for the coaxiality of the inner and outer circles of the gear blank, while the precision requirements for the fixture are not high, making it suitable for single-piece and small batch production.

The gear module is calculated using the formula: \[ m = \frac{d}{N} \] Where: - \( m \) is the module, - \( d \) is the pitch diameter of the gear, - \( N \) is the number of teeth on the gear.

2022-08-10

What is the gear module? How is it calculated? What is the calculation formula? For friends who are new to gear processing, it may not be very clear. Next, the gear processing manufacturer Shouyue Electromechanical will share the calculation formula for gear modules for reference and understanding. 1. What is the gear module? The gear module is an abstract measure used to quantify the size of gear teeth. It is a factor that determines the size of the teeth and is one of the most basic parameters for gear teeth manufacturing. The gear module is related to several important parameters that make up gear products, such as the pitch circle, pressure angle, number of teeth, and tooth pitch. 1. The standard module series is formulated based on requirements for design, manufacturing, and inspection. The modules for spur gears, helical gears, and bevel gears can all refer to the standard module series table. 2. Many custom mass-produced gears use non-standard modules. 3. For gears with non-spur teeth, there are differences in normal module mn, face module ms, and axial module mx, all of which are based on their respective tooth pitches (normal tooth pitch, face tooth pitch, and axial tooth pitch) and the ratio to pi, measured in millimeters. 4. For bevel gears, there are distinctions between large end module me, average module mm, and small end module m1. 2. How to calculate the gear module? What is the calculation formula for the gear module? 1. Calculation formula for helical gear module: a. Pitch circle diameter calculation Do = (number of teeth Z * module m) / cosB b. Diameter calculation Dk = ((number of teeth Z * module m) / cosB) + (module m * 2) c. Circumference of the gear when it rotates one circle Z = pitch circle diameter Do * π Note: The calculation for the installation center distance from the gear center point to the bottom surface of the rack is: installation center distance Hb = (pitch circle diameter Do / 2) + meshing center line Ho. 2. Calculation formula for spur gear module: a. Pitch circle diameter calculation Do = number of teeth Z * module m b. Diameter calculation Dk = (number of teeth Z * module m) + (module m * 2) c. Circumference of the gear when it rotates one circle Z = pitch circle diameter Do * π Note: The calculation for the installation center distance from the gear center point to the bottom surface of the rack is: installation center distance Hb = (pitch circle diameter Do / 2) + meshing center line Ho. If the number of teeth of the gear is fixed, the larger the module, the larger the radial size of the wheel; the larger the module, the higher and thicker the gear teeth; with a constant module, the larger the number of teeth, the more gradual the involute, and the thickness of the tooth tip circle and tooth root circle will correspondingly increase; with a fixed number of teeth, the larger the module, the larger the gear teeth, the stronger the resistance to breakage, and of course, the gear blank will also be larger, resulting in larger spatial dimensions. Therefore, when selecting gear processing products, it is necessary to consider various parameters comprehensively and choose the appropriate model specifications based on the actual application requirements.

Introduction to the Types and Characteristics of Precision Gears

2022-07-29

1. Helical Gears: Helical gears are widely used in various applications. Although they may appear more complex than other types of gears, they are very convenient to use. Helical gears can intermesh on two axes in space, whether they are perpendicular or parallel. Additionally, the direction of the small gears can be the same or opposite. Therefore, the impact of these gears is quite significant. 2. Spur Gears and Bevel Gears: Compared to the helical gears mentioned above, spur gears and bevel gears seem to have a more monotonous function. This is because spur gears were invented first. The two large and two small gears of this type can only be used on parallel axes, with both gears rotating in the same direction. Although they have been in production for a long time, they are still used, albeit in smaller quantities. 3. Characteristics of Bevel Gears: In fact, bevel gears and spur gears are similar in function, with one being straight and the other being angled. In some cases, you may need a bevel gear, while in others, a spur gear is required. Besides these two types, there are also bevel gears, which have a unique hammer-like shape. There are many types of precision gears, but the three mentioned above are common and play an important role. Therefore, these three types are familiar and widely used. If you want to purchase precision gears, you can choose based on actual needs, as long as you find the right size and model, it will bring convenience to people.