Service: Custom Cold Forged Ring Gears,Fabricate Pinion Gears
Short Description: Use Cold forged technology to fabricate metal ring gears and pinion gears.Highly impact forging in cold temperature,strong and solid,widely used in the field of auto,machinery,electronic, aerospace,industry,and so on.
Expereinced Items(The following parts are we already did,they are only a small part,more types are not displayed):
Benefits of custom cold forged socket,cold heading metal housing socket
Most of machined parts could be re-designed and re-manufactured to be parts made by technology of cold heading,which help you to get significant cost savings.
Improve production effience and reduced Production costs:Because of using high speed manufacturing process. The speed reaches range from 10 pieces per minute for low volume large press work to to 450 pieces per minute on the cold heading process.
Save material cost: Compared to a traditional machining process, cold forming process can save up to 70%.
Better control product tolerance: compared to more expensive machining processes,less tolerance can be achieved throughout the production process by coldforming
Higher and better quality surface: compared to conventional machined surfaces ,cold forming process can get result . The cold forming process can eliminate the need for costly secondary operations, such as welding, machining, etc, with careful product and process design,
Improved part performance and characteristics: due to the metal deformation resulting in improved grain structure, while work hardening can yield significantly improved product performance,cold forming process can improve metal part performance and its characteristics.
See how the technology of cold forging/cold heading to save materials cost:
Advantages of cold heading
Speed
Depending upon the size and complexity of the part and the nature of the equipment of producing them, production rates of 4000 pieces per hour can be achieved.
Economy
When compared to casting and machining labor the metal savings alone justify the conversion to an impact extrusion.In some cases when the aluminum slug is sized accurately, little or no trimming or other secondary operations are required.
Strength
The impact process naturally work hardens non-heat treatable alloys, while the heat treatable alloys can be heat treated in normal fashion after processing.
Toughness
The impact extruding process produces parts that are dense and porous-free in structure. This condition cannot be obtained in a casting process or by machining of a bar material.
Versatility
After impacting, the product can be treated the same as any other piece of material. Secondary operations such as machining, grinding, welding, bending, plating or anodizing can be performed in the same way as any other piece manufactured by a more conventional process.
Consolidation
Impacts can directly replace machined components, or welded or riveted assemblies, in many designs. The process often reduces product costs for secondary machining operations and in many cases increases the strength of a product that was previously an assembly.
General knowledge on “Ring Gears,Pinion Gears”
Category: Gear tooth can gear shape, tooth line shape, where the tooth surface and manufacturing methods classification. Toothed gear tooth profile include, pressure angle, tooth height and displacement. Involute gear relatively easy to manufacture, and therefore the use of modern gear, involute gear absolute majority, and cycloid gear and arc gear is seldom used. In terms of the pressure angle, pressure angle gear carrying capacity is small; and a large gear pressure angle, although the higher carrying capacity, but at the same torque transfer case bearing the load increases, so only used in special circumstances. The high gear tooth has been standardized, generally using standard tooth height. Advantages shifted gear more, throughout all types of machinery and equipment.
In addition, the gear can be divided according to their shape cylindrical gears, bevel gears, non-circular gears, rack, worm; shape into a straight line by tooth gears, helical gears, miter gears, gear curve; according to the teeth where outer surface is divided into gear, internal gear; manufacturing methods can be divided according to the casting gear, gear cutting, rolling gear, sintered gears. Gear manufacturing materials and heat treatment process has a great impact on the carrying capacity and size of the weight of the gear. Before the 1950s, gear and more carbon steel, alloy steel switch 60s, and 70s multi-hardened steel. According to the hardness of the tooth surface can be divided into two kinds of soft and hardened tooth surface. Lower gear carrying capacity of soft tooth surface, but relatively easy to manufacture, running-good, more for driving without strictly limited in size and weight, as well as a small amount of production of general machinery. Because paired gear ferry heavier burden, so as to make the working life of roughly equal size gears, small tooth surface hardness is generally higher than for large wheel. Hardened gear of high carrying capacity, it is fine cut after the gear, and then quenching, surface hardening or carburizing and quenching treatment to improve the hardness. However, in the heat treatment, the gear will inevitably deformed, so after the heat treatment to be ground and polished or fine cut, in order to eliminate errors due to deformation, improvement of the precision gear.
Materials: Manufacture of gears commonly used steel has quenched and tempered steel, hardened steel, case hardening steel and nitriding steel. Slightly lower than the forged strength steel, commonly used in larger size gear; the poor mechanical properties of gray cast iron, can be used for light load of gear in the open; ductile iron may be partially replaced by steel gear; multi-purpose plastic gears at light load and low noise requirements where the gear is generally paired with good thermal conductivity of steel gears. Coming forward gear overloading, high speed, high precision and high efficiency, direction, and strive to small size, light weight, long life, and economic and reliable. And the development of theory and gear manufacturing process will be further studied the mechanism of tooth damage, which is to establish a reliable calculation method is based on the strength, improve gear carrying capacity and prolong the life of the theoretical basis of the gear; the development of arc tooth profile represented the new tooth; study new materials and manufacturing gear gear new technology; elastic deformation of gear, manufacture and installation errors and the distribution of temperature field, perform tooth modification to improve the smoothness of running gear and at full load when increasing the contact area of the tooth, thereby improving the carrying capacity of the gear. Friction, lubrication theory and gear lubrication technology research infrastructure work, study elastic hydrodynamic lubrication theory, promote the use of synthetic lubricants and extreme pressure additives, due to join in oil, not only can increase the carrying capacity of the tooth surface, and can improve transmission efficiency.
Processing methods:
Involute gear machining method has two categories, one is the profiling method, with the alveolar molding gear milling cutter is “imitation shaped”. Another is generating method (generating method). (1) hobbing hobbing: 8 modulus can be processed following the helical (2) milling machine milling: rack can be processed straight (3) slotting slotting: can be processed within the tooth (4) cold hit machine fight tooth: You can chipless (5) planing machine planing tooth tooth: 16 modulus can process large gear (6) Precision Casting teeth: you can process large quantities of cheap pinion (7) grinding machine grinding teeth: precision machine tools can be processed on a gear (8) die casting machine casting gear: Most non-ferrous metal processing gear (9) shaving machine: a gear finishing with a metal cutting machine tools
The main parameters
Teeth Z
Closed gear is generally high speed, in order to enhance the smooth transmission, reducing shock and vibration, with a little more teeth as well, the number of teeth of the pinion desirable for z1 = 20 ~ 40. Open (semi-open) gear, mainly because of tooth wear failure, not too small for the gears, so the pinion teeth should not use too much, is generally preferable to z1 = 17 ~ 20. Helix angle
β> 0 for L; β <0 for right-handed
Spiral bevel gear Pitch
pn = ptcosβ (subscript n and t, respectively, and the end of the notation) Modulus
Modulus refers to the adjacent teeth or two teeth between the tooth profile of the same side of pitch p and pi π ratio (m = p / π), in millimeters. Modulus is a modular system of a basic parameter of teeth, straight teeth, mold and tapered helical gears few Jieke reference standard modulus Series table (GB / T 1357-1987). mn = mtcosβ m = p / π Pitch circle gear is designed to calculate the various parts of the base size gears and gear indexing circumference of a circle = πd = zp Modulus m is the size of a basic gear decision parameters. The same number of teeth of the large gear module, its size is also large. Pressure Angle
α rb = rcosα = 1 / 2mzcosα In the two gear pitch circle tangent point P, two tooth profile of normal line (ie, the direction of the tooth profile of the force) and two common tangent of the pitch circle (ie the instantaneous direction of movement at the point P) sandwiched called acute angle pressure angle, also known as meshing angle. Single gear is the profile angle. Standard gear pressure angle is generally 20. “In some cases there is also an α = 14.5 °, 15 °, 22.50 ° and 25 ° and so on. Pitch circle diameter
d = m * z Center distance
a = 1/2 * m (z1 + z2) Properly engaged condition
m1 = m2, α1 = α2, β1 = β2 To make the gear from undercutting, for α = 20o standard cylindrical gear ruler should take z1≥17. Z2 = u · z1. Addendum coefficient and headspace coefficient -h * A, C * When the two gears, one gear tooth tip always enters another gear tooth root, in order to prevent thermal expansion and having a top die into the lubricating oil storage space requirements of the tooth root height greater than the addendum. This addendum to the introduction of high coefficient and coefficient of headspace. Normal teeth: h * a = 1; C * = 0.25 short teeth: h * a = 0.8; C * = 0.3
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