Manufacturing process of large helical gears in Dalian

Manufacturing process of large helical gears in Dalian

In many fields of modern industry, large helical gears play an important role. They are widely used in the transmission systems of large equipment such as heavy machinery, ships, and wind power generation. Their manufacturing process and performance characteristics directly affect the operational efficiency, stability, and reliability of the entire equipment.

Manufacturing process of large helical gears

（1） Material selection

To manufacture large helical gears in Dalian, the first step is to carefully select suitable materials. High strength alloy steels such as 42CrMo and 17CrNiMo6 are usually selected, which have excellent strength, toughness, and wear resistance, and can withstand large loads and complex working environments.

（2） Preparation of raw materials

Common methods for preparing raw materials include forging and casting. Forging can improve the microstructure and mechanical properties of materials, but the cost is relatively high; Casting is suitable for situations with complex shapes and large batches, but there may be internal defects that require subsequent testing and processing.

（3） Tooth profile machining

Gear hobbing: This is a commonly used method of cutting tooth profiles by the relative rolling of a rolling cutter and a gear blank. For large helical gears, it may be necessary to use a large gear hobbing machine to ensure machining accuracy.

Gear hobbing: suitable for machining internal teeth and multiple gears, capable of achieving high tooth profile accuracy.

（4） Heat treatment

Heat treatment is a key step in improving gear performance. Common heat treatment processes include carburizing quenching, quenching and tempering treatment, etc. Carburizing and quenching can achieve high hardness and wear resistance on the surface of gears, while maintaining good toughness in the core; Quenching and tempering treatment can improve the overall comprehensive mechanical properties.

（5） Precision machining of tooth surface

In order to improve the accuracy and smoothness of the tooth surface, precision machining processes such as grinding and honing are usually carried out. This helps to reduce noise, improve transmission efficiency, and extend service life.

（6） Testing and Quality Control

During the manufacturing process, strict testing is required, including dimensional accuracy, tooth profile accuracy, hardness testing, etc. Testing equipment such as coordinate measuring machines and gear measurement centers can ensure that the quality of gears meets design requirements.