Gear Assembly
Gears are an integral system component used to transfer rotational power or calculate speed ratios in machines. Through careful assembly and intimate knowledge of the limitations of a particular gear type, engineers and mechanics can ensure that the equipment that utilizes a set of gears will operate properly and last for many years.
Assembly of a gear set is relatively straightforward, though following a few guidelines will help to ensure that the job is done properly the first time. Most sets of gears are far too large to assemble by hand, requiring the use of some type of mechanical press. For smaller gears, a vice or simple arbor press can be used.
The first step in the assembly process is to clean the components to ensure none are contaminated or damaged. This is especially important if a lubricant will be used, as contaminants can cause wear or even seizing of the gears. As long as no damage is present, the gears should be free of burrs, grooves, or other imperfections.
Next, gears must be properly aligned with each other. This is usually done with a set of complementary pins. The pins are inserted into the outer edges of the gears in a uniform manner to ensure equal distances between them. This will help to prevent any excessive binding during operation.
The next step is to place the gears in the press. Depending on the type of press being used, the gears can be placed in either side-by-side or adjacent formations. If adjacent, one gear must be placed inside the other, rotated 180 degrees so that they are pressed together properly. If a lubricant will be used, it should be applied to each gear before they are pressed together.
Once the gears are properly placed, the press can be used to slowly and evenly apply pressure to the gears until they are fully seated. This must be done gradually, as a sudden pressure application could cause them to jam or strip. When the pressure has reached a sufficient level, the press can be released and the gears can be removed.
Finally, the newly assembled gears should be tested to ensure they are not overstressed. This can typically be done by manually rotating them several times in both directions to determine that they are not unduly binding when rotating. If any excessive binding is noticed, the gears should be adjusted or replaced as applicable.
Assembling a set of gears is a relatively simple process that can yield tremendous results. By following the process outlined above, properly assembled and functioning gears can be easily achieved, allowing for proper operation of the machine and prolonging its useful life.
