The Materials and Processing Technology of Gears for Automobiles
Introduction
Drive trains in automobiles depend on gears to properly shift the power from the engine to the wheels. Without gears in the drive train, automobiles wouldnt be able to be driven or maneuvered. Gears for automobiles come in a multitude of sizes and materials, depending on the vehicle and its drivetrain. It is important for automobile engineers and designers to understand the materials and processing technology involved in manufacturing gears so that they can choose the right gear material and make sure that it is processed properly.
Gears Materials
Before looking at how gears are processed, it is important to understand the materials that they can be made from. The most common materials used in the manufacturing of gears are steel, aluminum, and plastic.
Steel: Steel is the most common material used to make gears. It is strong, durable, and relatively inexpensive. When steel gears are manufactured, they are usually heat-treated to increase their hardness and strength.
Aluminum: Aluminum is a lightweight metal that is often used for lighter-duty gears and for those in applications requiring weight reduction. Although aluminum is not as strong or durable as steel, it can be machined more quickly than steel, resulting in faster turnaround times.
Plastic: Plastic is often used for lighter applications, such as in small gearboxes or toys. It is a lightweight, inexpensive material that is easy to machine and form.
Gears Processing Technology
Now that we have looked at the materials used to make gears, lets look at the processes involved in their manufacturing. The most common processes used to manufacture gears are milling, hobbing, shaping, and grinding.
Milling: Milling is used to cut the teeth on the outside surface of a gear. It is an especially accurate process that can be used to make small or large gears.
Hobbing: Hobbing is a machining process that uses a special cutting tool to cut the teeth on the inside of the gear. This process is often used to make large gears since it is very accurate and produces smooth, clean cuts.
Shaping: Shaping is a process used to cut the teeth on the outside surface of a gear. This process is often used to make small gears since it is faster and less costly than milling or hobbing.
Grinding: Grinding is a finishing process used to smooth the edges of the teeth and make sure they are sharp and precise. This process is essential in making sure that the teeth mesh properly when the gears are in operation.
Conclusion
Gears are an essential component of any automobile drivetrain. They are usually made from steel, aluminum, or plastic and are manufactured through milling, hobbing, shaping, and grinding processes. Automobile engineers and designers need to understand the materials and processing technology involved in making gears in order to choose the right gear material and make sure that it is processed properly.
