Introduction to Gears

First Edition
 Preface

The history of gears is probably as old as civilization itself. And yet today, the
importance of gears in manufacturing industry is undwindling and even more growing.

The purpose of this handbook is to provide an outline of gear fundamentals for those
who want to acquire knowledge about mechanics of gears. In reading through this
handbook, if you have any questions please refer them to us and we would be happy to
respond.

We hope this can start you down the road with a good sence of direction.
 Contents
Part 1 About Gears
1. Types of Gears...........................................................................................................4
2. Characteristics of Each Type of Gears.......................................................................7
3. Gear Terminology.....................................................................................................11
4. Involute Tooth Profile...............................................................................................14
5. Pressure Angle..........................................................................................................16
6. Profile Shifted Gears................................................................................................17
7. Gear Accuracy - Testing and Inspecting..................................................................19
8. Metallic Materials for Gears and Heat Treatment...................................................21
9. Gear Noise...............................................................................................................24
10. Q & A ......................................................................................................................26
Part 2 Production Processes 27
1. Spur Gears................................................................................................................28
2. Racks........................................................................................................................30
3. Bevel Gears..............................................................................................................32
4. Production Facilities.................................................................................................34
 Part 1
About Gears
1. Types of Gears
2. Characteristics of Each Type of Gears
3. Gear Terminology
4. Involute Tooth Profile
5. Pressure Angle
6. Profile Shifted Gears
7. Gear Accuracy - Testing and Inspecting
8. Metallic Materials and Heat Treatment
9. Gear Noise
10. Q & A
(1) About Gears

Shape of bevel gear .....

Spur Gear Helical
( 1 ) - 1
Types of Gears

Spur Gear Helical Gear Rack

Bevel Gear Spiral Bevel Gear Screw Gear

Miter Gear Worm & Worm Wheel Internal Gear

--
 Worm
Internal Gear

Worm Wheel Gear Coupling

Miter Gear

Involute Spline Shafts

Screw Gear & Bushings Helical Gear

Pawl Rack
Pinion Spur Gear

--
Rachet

Involute Spline Shafts

& Bushings

Spiral Bevel Gear

Straight Bevel Gear

(1) About Gears
 (1) About Gears

There are three categories of gears in accordance with the orientation of axes.

1) Parallel Axes MSGA(B),SSG(S),SS,SSA,SSY,SSAY,

LS,SUS,SUSA,SUSL,DSL,NSU,PU,
Spur Gear PS,PSA,DS,BSS,SSCPG(S),SSCP,
SUSCP,SSR,KTSCP

Helical Gear KHG,SH

KRG(F),KRGD,SRGF,KRF,SR(F),
SRFD,SUR(F),SURFD,BSR,DR,
Rack PR(F),SRO,SROS,SURO,KRHG(F),
SRH,KRG(F)(D),SRCP(F)(D),KRCPF,
SURCPF(D),SRCP,FRCP

Internal Gear SI,SIR

2) Intersecting Axes MMSG,SMSG,MMSA(B),

Miter Gear MMS,SMS,SMA(B)(C),MM,LM,
SM,SAM,SUM,PM,DM

Straight Bevel Gear SB,CB,SBY,SUB,PB,DB

Spiral Bevel Gear MBSG,SBSG,MBSA(B),SBS,KSP

3) Nonparallel,
Nonintersecting Screw Gear AN,SN,PN,SUN
Axes

Worm KWGDL(S),KWG,SWG,SW,SUW

Worm Wheel AGDL,AGF,AG,PG,CG,BG

4) Others
Involute Spline Shaft
SV,SVI
& Bushing

Gear Coupling GC,GC-I

Pawl & Rachet SRT,SRT-C

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 (1) About Gears

( 1 ) - 2
Characteristics of Each
Type of Gears

Spur Gear
Teeth are straight and parallel to shaft axis. Transmits power and motion
between rotating two parallel shafts.

Features
( 1 ) Easy to manufacture. ( 2 ) There will be no axial force.
( 3 ) Relatively easy to produce high quality gears. ( 4 ) The commonest type.
Applications
Transmission components

Helical Gear
Teeth are twisted oblique to the gear axis.
Left
Helix angle
Left

The hand of helix is designated

as either left or right.
Right

Right

Right hand and left hand helical gears mate as a set. But they have the
same helix angle.
Features
( 1 ) Has higher strength compared with spur gear.
( 2 ) Effective in reducing noise and vibration compared with spur gear.
( 3 ) Gears in mesh produce thrust forces in the axial directions.

Applications
Transmission components, automobile, speed reducers etc.

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(1) About Gears

Rack
The rack is a bar containing teeth on one face for meshing with a gear.
The basic rack form is the profile of the gear of infinite diameter.
Racks with machined ends can be joined together to make any desired
length.

Features
( 1 ) Changes a rotary motion into a rectilinear motion.
Applications
A transfer system for machine tools, printing press, robots, etc.

Internal Gear
An annular gear having teeth on the inner surface of its rim.
The internal gear always meshes with the external gear.

Features
( 1 ) In the meshing of two external gears, rotation goes in the opposite direction. In the
meshing of an internai gear with an external gear the rotation goes in the same direction.
( 2 ) Care should be taken to the number of teeth when meshing a large (internal) gear with
a small (external) gear, since three types of interference can occur.
( 3 ) Usually internal gear is driven by external (small) gear.
( 4 ) Allows compact design of the machine.
Applications
Planetary gear drive of high reduction ratios, clutches etc.

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 (1) About Gears

Bevel Gear
One of a pair of gears used to connect two shafts whose axes intersect, and
Apex
the pitch surfaces are cones.

Pitch cone
Teeth are cut along the pitch cone. Depending on tooth trace bevel gear is
classified:
1) Straight bevel gear
2) Spiral bevel gear

1 ) Straight Bevel Gear

A simple form of bevel gear having straight teeth which, if extended
inward, would come together at the intersetion of the shaft axes.

Features
( 1 ) Relatively easy to manufacture. ( 2 ) Provides reduction ratio up to approx. 1:5.
Applications
Machine tools, printing press, etc. Especially suitable for a differential gear unit.

2 ) Spiral Bevel Gear

Bevel gear with curved, oblique teeth to provide gradual engagement and
bring more teeth together at a given time than an equivalent straight bevel
gear.

Features
( 1 ) Has higher contact ratio, higher strength and durability than an equivalent straight
bevel gear.
( 2 ) Allows a higher reduction ratio.
( 3 ) Has better efficiency of transmission with reduced gear noise.
( 4 ) Involves some technical difficulties in manufacturing.
Applications
Automobile, tractor, vehicles, final reduction gearing for ships.

Miter Gears
A special class of bevel gear where the shafts intersect at 90° and the gear
ratio is 1:1.

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(1) About Gears

Screw Gear
A helical gear that transmit power from one shaft to another, non-parallel,
non-intersecting shafts.

Features
( 1 ) Used in a speed reducer and/or a multiplying gear.
( 2 ) Tends to wear as the gear come in sliding contact.
( 3 ) Not suitable for transmission of high horsepower.
Applications
Driving gear for automobile. Automatic machines that require intricate movement.

Worm Gear Pair

Worm Worm is a shank having at least one complete tooth (thread) around the
pitch surface; the driver of a worm wheel.
Worm wheel is a gear with teeth cut on an angle to be driven by a worm.
Center distance

Worm Wheel

Features
( 1 ) Provides large reduction ratios for a given center distance.
( 2 ) Quiet and smooth action.
( 3 ) A worm wheel is not feasible to drive a worm except for special occasions.

Applications
Speed reducers, anti-reversing gear device making the most of its self-locking features, machine tools,
indexing device, chain block, portable generator, etc.

- 10 -
 (1) About Gears

( 1 ) - 3
Gear Terminology

Facewidth
α Pressure angle
Tip
Re

cir
fer

cle
enc
ec
i
Bas ot circle

rcle
Ro
e ci
rcle

Tip
Reference pitch

dia
me
Re
fe

ter
re
nc
ed
iam
Ba ete
se r
dia
me
ter
Roo
t dia
mete
r

Center line
t
ntac

Pitch point
of co

Backlash
p ath
h of
Lengt

Interference point

Tooth thickness
Dedendum
Center distance

Tooth depth
Addendum

- 11 -
 (1) About Gears

The Module Reference diameter.

Let me see ...

of a Gear

The number of teeth

1 2 3

"Module" is the unit of size to indicate how big or small a gear is. It is the ratio of the reference
diameter of the gear divided by the number of teeth.
Reference diameter
Thus: (Module =──────────── )
Number of teeth
The mutual relation between the module and the reference diameter etc. is as follows:
Reference diameter ( Reference diameter = Module × Number of teeth )
Reference diameter
Number of teeth ( Number of teeth = ──────────── )
Module
Reference pitch ( Reference pitch = π × Module )

Then, what is the reference pitch?

It is equal to the circumference divided by
Circumference
the number of teeth.

Circumference (pd)
Reference pitch Reference pitch = ─────────
Number of teeth (z)
Diameter

Then, what is the reference circle?

This is a friction pully. As the surfaces are smooth, the rotation
will not go properly when great force is applied. This problem will
be solved if there are teeth on the periphery of the friction pully. And
this is the concept of gearing.
Friction pully (Reference circle)

Both reference circles come in contact

Summary
( 1 ) The module describes the size of a gear.
( 2 ) A pair of gears can only mesh correctly if and when the base pitch is the same.

- 12 -
 (1) About Gears

Practicing What You've Learned

Spur Gear
Module Pinion Gear

(a) Reference diameter

Number of teeth × Module

(b) Tip diameter

Reference diameter + a double module

(c) Center distance

Add reference diameters then divide by two

Helical Gear
Module Pinion Gear Helix angle β
when cos β
(a) Reference diameter

(b) Tip diameter

(c) Center distance Center distance

- 13 -
 (1) About Gears

( 1 ) - 4
Involute Tooth
Profile

Imagine pulleys with indentations on their periphery. These pulleys, when moved, would:

cause slipping,
do not rotate smoothly,
produce vibration and noise.

They are improper and unsuitable as a gear.

Satisfactory gears must transmit power smoothly. The involute curve meets all the requirements for a
gear-tooth profile.
The involute curve:
Cord
If a cord is wrapped around a cylinder, as shown in this figure, a point on the
cord, as it is unwrapped from the cylinder, traces a curve called an involute.
The circle from which the string is unwound is called the base circle.

Involute curve

Ba
se
cir
Let us try to make a simple drawing of a eight-toothed gear; cle

First, divide a cylinder into eight equal parts. Then, from each part unwrap a cord drawing a line
with pencil. After you have completed eight lines, do the same manual work from the opposite side. The
diagram thus drawn is the involute tooth profile.

- 14 -
 (1) About Gears

Involute Gear
This figure indicates how two involute teeth in mesh are moving to transmit rotary motion.

cle
t cir
o le
Ro irc
c
Drive gear se cle
Tan
gen Ba e cir
t nc
re
e fe
R

Re
f er
en
ce
Tan c
gent ircle
Driven gear Ba
se
cir
Ro cl e
ot
cir
cl e

→ → moving in this order

When Gear 1 drives Gear 2 by acting at the instantaneous contact point, the contact point moves on
the common tangent in the order of → → . These points are on the common tangent outward from
the base circle.

It is like P point of a belt on the periphery of two discs is travelling.

The involute profile makes it possible to transmit rotary motion
smoothly.

Belt

Features
( 1 ) Conjugate action is independent of changes in center distance.
( 2 ) Can be manufactured at low cost since the tooth profile is relatively simple.
( 3 ) A typical tooth profile used almost exclusively for gears.

- 15 -
(1) About Gears

( 1 ) - 5
Pressure Angle

The pressure angle between the tooth profile and a

radial line at its pitch point. In involute teeth it is often
f described as the angle between the line of action and
al o
o rm file
N pro the line tangent to the pitch circle.
the
Here . Therefore, also is the pressure
angle.
Tangent to the reference circle
Tan
Radial line

gen
t

This figure indicates the meshing of a gear A and a gear B

at the pitch point.

al
o rm
n n cle
mm
o
e cir
Co c
en
efer
R

r ef e
ren
ce
ci r
cl e

At the pitch point, the gear A is pushing the gear B. The pushing force acts toward the common
normal of the gear A and the gear B. The pressure angle can be described as the angle between the line
of action and the line tangent to the reference circle.

For reference
The commonest pressure angle is 20 . Formerly the pressure angle of 14.5 was also used.
o o

- 16 -
 (1) About Gears

(1)-6
Profile Shifted
Gears

When the number of gear teeth to be cut becomes small,

the generating tool will sweep out its path, remove some of
the profile, and produce an undercut tooth form. To prevent
undercut, some correction must be introduced, and it is called
profile shifting. Profile shifting can not only prevent undercut,
but also can adjust center distance between two gears.

Example of undercut gear Example of gear without undercut

An example of profile shifting is given here.

The positive correction of 0.5 is to be made on 10-toothed gear( )

The calculations to be made:
( I ) Determine working pressure angle ( II ) Find center distance
modification coefficient y

( III ) Determine center distance a ( IV ) Find tip diameter

- 17 -
 (1) About Gears

Negative shifting Positive Shifting

(Tooth thickness is thinner) (Tooth thickness is thicker)
There are both positive and negative
shifting.
There will be change in tooth
thickness; In the case of positive
Reference circle

Reference circle
shifting (+), tooth thickness will
become thicker, while in the case of

Shifted gear
negative shifting (-), it will become
thinner. Tooth depth will not change.
Standard gear
Shifted gear

Standard gear
The amount of shift

The amount of shift

Tooth depth Tooth depth

Center distance
This figure shows that a gear is
negative shifted and a pinion positive
shifted, and the absolute value of
profile shift is identical. Attention is
to be paid that there is no change in
center distance. If there is a condition
that center distance is invariable, the
profile shifting will solve the problem
as illustrated here.
Positive shift
Negative shift

Gear Pinion

The meshing of standard spur gear means

reference circles of two gears contact and
Reference circle roll with each other. The same of the profile
shifted spur gear means working pitch circles
of two gears contact and roll with each other.
Working pitch circle
The pressure angle at the working pitch circle
is called working pressure angle. And this is
different from reference pressure angle. In
designing profile shifted gear this working
Reference circle
pressure angle will be an important
factor.

Features
( 1 ) Prevents undercutting when the number of teeth is small.
( 2 ) Helps adjusting center distance
( 3) Possible to equalize the strength of a pinion and the same of a gear by profile shifting; Make
correction (shifting) of the pinion positive. Then make correction of the gear negative. This results in
thicker tooth thickness of the pinion and the thinner tooth thickness of the gear, or equalization of the
strength.

- 18 -
 (1) About Gears

( 1 ) - 7
Gear Accuracy
- Testing and
Inspecting

At KHK, the following measuring instruments are used to test and inspect the gear accuracy.
( 1 ) Gear measuring machine......To measure the accuracy of tooth profile, trace, pitch and runout.
( 2 ) 3-D coordinate measuring machine To measure the pitch accuracy of racks
( 3 ) Composite gear tester To test composite deviation

3-D coordinate measuring machine Gear measuring machine

The measuring apparatuses used while working on a gear production are:

(1) Vernier calipers, Mircometer calipers, Cylinder gauge........To measure inside and outside diameters and tooth thickness.
(2) Runout tester......................To measure side face runout, and circumference (radial) runout.
(3) Hardness testing machine.................................... To measure hardness
(4) Micrometer calipers ........................................... To find span measurement
(5) Gear tooth vernier calipers.................................. To measure tooth thickness of worm
(6) Worm gear tester................................................. To measure tooth contact and backlash
(7) Bevel gear tester.................................................. To measure tooth contact and backlash

Vernier calipers Cylinder

gauge
Micrometer Gear tooth vernier Runout tester
calipers calipers

- 19 -
 (1) About Gears

Gear Accuracy in 3-D

( 3 ) Circumferential direction - relevant to

Circu tooth thickness and spacing
mfer
entia
l dire
ction

Axial direction
n
tio
ec
dr
al
di
Ra
( 1 ) Radial direction - relevant to tooth
proile and tooth depth
( 2 ) Axial direction - relevant to
lead error and unevenness

In order to test gear accuracy three-dimentional measurements are necessary, and the following
mesuring instruments and/or apparatuses are to be used properly.
( 1 ) Radial direction ................ Gear measuring machine, 3-D coordinate measuring machine
( 2 ) Axial direction ................... Gear measuring machine, 3-D coordinate measuring machine
( 3 ) Circumferential direction .... Micrometer calipers, gear tooth vernier calipers, rollers
(pins), ball micrometer calipers.
Shown in this figure is the correlation between each individual errors. There is a strong correlation
between each pitch errors. Also, runout error widely influence each individual errors.

Correlation between Errors

Single pitch
deviation

Adjacent pitch Total cumulative

deviation pitch deviation

Runout error of
gear teeth

Base pitch
Total helix
deviation
deviation

Total profle
deviation Strong correlation

Mean correlation

A slight correlation
Correlation between each individual errors (in case of ground gear)

- 20 -
 (1) About Gears

(1)-8
Metallic Materials
for Gears and Heat
Treatment
The materials herein described are generally used domestically.

Case-hardening steel
The carbon content of case-hardening steel is low, usually about 0.15 through 0.20%. Case-hardening
steel also contains Ni,Cr,Mo,Mn, etc. It is suitable for carburizing and quenching.
Chemical composition %
JIS Designation
C Si Mn P S Ni Cr Mo
SCr420 0.18 0.23 0.15 0.35 0.60 0.90 <0.030 <0.030 - 0.90 1.20 -
SCM415 0.13 0.18 - 0.15 0.25
SCM420 0.18 0.23 -
SNC815 0.12 0.18 0.35 0.65 3.00 3.50 0.60 1.00 -
SNCM220 0.17 0.23 0.60 0.90 0.40 0.70 0.40 0.60 0.15 0.25

Aluminium bronze casting

Hardness
Chemical composition % Tensile test
test
Descriptions Symbol Tensile Applications
strength HB
Cu Al Fe Ni Mn Others Elongation
10/1000
N/
Gear, bearing, bush, valve
Aluminium seat, impeller, propeller for
ships etc.
bronze 80.0 8.0 2.5 1.0
CAC702 <1.5 >0.5 >490 >20 >120 (Suitable for those which
casting 88.0 10.5 5.0 3.0 require
Type 2 rust, erosion and/or wear
resistance.)

Bronze casting
Chemical composition % Tensile test
Tensile
Descriptions Symbol strength Applications
Cu Sn Zn Pb Others Elongation
N/
Valve cock, machine parts
Bronze etc. (Suitable for those which
continuous
CAC406C 83.0 87.0 4.0 6.0 4.0 6.0 4.0 6.0 >2.0 >245 >15 require pressure resistance,
casting
machinability and suitability
Type 6
to casting.)

- 21 -
 (1) About Gears

Carbon steels for machine structual use

The most commonly used material. KHK mainly uses S45C. Suitable for high-frequency induction hardening.
Chemical composition %
Symbol
C Si Mn P S
S43C 0.40 0.46 0.15 0.35 0.60 0.90 <0.030 <0.035
S45C 0.42 0.48
S48C 0.45 0.51

Chromium molybdenum steel

Chromium molybdenum steel is thermal-refined and then hardened by high-frequency induction hardening.
Chemical composition %
Descripions Symbol
C Si Mn P S Cr Mo
Type 3 SCM435 0.33 0.38 0.15 0.35 0.60 0.90 <0.030 <0.030 0.90 1.20 0.15 0.30
Type 4 SCM440 0.38 0.43

Quenching
Quenching is the process to surface-harden tooth areas to increase their strength. Cited here are two,
among others, processes - (a) carburizing and quenching, and (b) high-frequency induction hardening.

Carburizing and Quenching.....

The suitable material - SCM415 etc.
Carburizing Quenching Cleaning Tempering Shot blast Testing/Inspecting
Case hardened steel is usually formed by diffusing carbon (carburizing) into the outer layer of the
steel at high temperature. And putting carbon into the surface of steel makes it a high-carbon steel
like S45C, which can be hardened by heat treatment.
Surface hardness………55 60HRC
Depth of surface hardening……Approx. 1.0

Features
Carburizing and Quenching produces a hard, wear-resistant surface over a strong tough core.

Carburizing & quenching furnace Hardened layers

- 22 -
 (1) About Gears

High-Frequency Induction Hardening..... The suitable matrial - S45C, SCM440 etc.

Electric
terminal
Hardened
Flat rolled layers
Gear silicon steel sheet
Water
Inductor
coil Gear

Inductor coil Gear

Inductor coil
Water
Hardened layers Dust core

( a ) One-shot entire perimeter hardening ( b ) One-shot single tooth hardening ( c ) Continuous hardening

Thermal refining → Hardening → Tempering

Features
When heated with the inductor coil, the steel is hardened. But hardened area is limited to the
surrounding area of the coil.
Sulphur (S) and phosphorus (P) may cause hardening cracks. Carbon (C) content is preferrable less
than 0.55%.
Various types of inductor coil are used depending on the shape of the gear. Some experience is
required to do this work as cracking and/or deformation are apt to happen.

Hardening apparatus Tempering furnace

- 23 -
 (1) About Gears

( 1 ) - 9
Krrrrrrrr Krrrrrrr
Gear Noise

This figure indicates the result of survey conducted by a manufacturer that produces gears for automobile,
machine tools and speed reducers.

Cause of noise and vibration

Configuration of gears
Accuracy of gears

Accuracy of assembly

Tooth surface finish

Configuration of gearbox

Lubrication of gears

Bearing

Matrial of gears

Motor and impact from load

Design of gears

Driving condition

Shaft and shafting

Wear of gears

Bruise

Others

Factors contributing to gear noise (%)

Design 35%
Fabrication 30%
Usage 20%
Assembly 15%

Technical problem:
Tooth contact Heat treatment
Tooth profile Shafting
Tooth surface finish Size of gearbox
Pitch Ball bearing, roller bearing
Center distance Rotational speed

- 24 -
 (1) About Gears

In order to manufacture gears that materialize quietness of operation:

Reduce the pitch error.
Reduce the tooth profile error.
Reduce the runout error. Chamfering
Reduce the lead error.
Modify tooth surface by crowning.
Crowning
Modify tooth surface by tip relieving.
Improve the smoothness of tooth by chamfering.
Eliminate the roughness on the tooth surface by grinding.
Increase the contact ratio - bigger contact ratio lowers the noise.
At the stage of designing, try to shape gearbox as round as possible.
At the stage of designing, try to decide what type of shockabsorber to be set up for
maximum effect.
Use flexible coupling properly between the shafts.
Take care to make the mounting holes of gearbox precisely so that it can be mounted correctly.
When setting up gears into gearbox, care must be taken that gears come in contact properly to
void edge contact.

Edge contact

This figure shows an example of data regarding noise

level as a result of test on KHK stock gears.
Noise level of KHK stock gears 1984 1985
: S45C without heat treatment.
)SS2.5-24, SS2.5-48)

: Plastic.
(PS2.5-24, PS2.5-48)
Decibel ( db )

: S45C Tooth surface high-frequency

induction hardened and ground.
(SSG2.5-24, SSG2.5-48)

: SCM415 Overall carburizing and

quenching, tooth surface ground
(MSGB2.5-24, MSGB2.5-48) n 1 ( rpm )

- 25 -
 (1) About Gears

( 1 ) - 10
Q & A

Q : Quietness of operation is very specific demand. What type of gear do you recommend ?
A : We recommend high-precision gears with better tooth-surface finish, the type tooth-surface is ground,
such as MSGA(B). Helical gears are effective for reduction of noise than spur gears. Plastic gears
are also quiet, though the strength decreases.

Q : What type of gear is rustproof ?

A : Stainless steel gears and plastic gears. Plastic gears can operate with continuous lubrication, initial
lubrication, or no lubrication. Meshing of plastic gears with plastic gears may cause generation of
heat, or dimentional changes as a result of moisture absorption. Meshing of a plastic gear with a
metal gear is recommended.

Q : I want to know about "backlash". Will you please explain a little about it ?
A : "Backlash" in assembled gear set is the clearanc between the teeth of the meshing gears. Some
backlash should be present in all gear meshes for smoother revolution.

Q : Do you carry any products that have the ablity to adjust backlash to minimum ?
A : KHK carries , as standard products, items with ability to adjust backlash such as Tapered Racks and
Pinions, and Duplex Worms and Worm Wheels.

Q : Will you please explain about the effect of heat quenching ?

A : In case of gears made from S45C such as SS spur gear, the quenching will increase strength 400%.
However, the precision grade such as pitch deviation will drop about one grade.

- 26 -
Part 2
Production
Processes

1. Spur Gears
2. Racks
3. Bevel Gears
4. Production Facilities
(2) Production Processes

( 2 ) - 1
Spur Gears
Illustrated here is a typical process of making SS type spur gears.

Raw Materials Sawing

Raw materials bought from material The materials are cut to size.
makers are kept in stock. The materials are
six meters in length.

Packaging

To ensure delivery in good condition

each and every spur gear is individually
packaged.

- 28 -
 (2) Production Processes

Shaping Tooth-Cutting

With a lathe, a cut workpiece is shaped Tooth-cutting has been done with a gear
into gear blank. hobbing machine. The cutting usually
leaves burrs on the teeth.

Black Oxide Finish Deburring

The black oxide finish is somewhat Rough spots on the teeth have been
effective in preventing rust. smoothed with a deburring machine.

- 29 -
(2) Production Processes

( 2 ) - 2
Racks
Illustrated here is a typical process of making SRFD type racks.

Raw Materials Tooth-Cutting

Raw Materials bought from material Tooth-cutting has been done with a rack
makers are kept in stock. cutting machine. The cutting usually leaves
burrs on the teeth.

Packaging Black Oxide Finish

To ensure delivery in good condition The black oxide finish is somewhat

each and every rack is individually effective in preventing rust.
packaged.

- 30 -
 (2) Production Processes

Deburring Straightening

Rough spots on the teeth have been To straighten warping, pressure is

smoothed with a deburring machine. applied on racks with a hydraulic press

Processing holes Machining Ends

Mounting screw holes have been drilled Both ends have been machined so that
for easier assembly. racks can be butted against each other to
make any desired length.

- 31 -
(2) Production Processes

( 2 ) - 3
Bevel Gears
Shown here is a typical process of making SM type bevel gears.

Raw aterials Sawing

Raw materials bought from material The materials are cut to size.
makers are kept in stock. The materials are
six meters in length.

Packaging

To ensure delivery in good condition

each and every bevel gear is individually
packaged.

- 32 -
 (2) Production Processes

Shaping Tooth-Cutting

With a lathe, a cut workpiece is shaped Tooth-cutting has been done with a
into gear blank. Coniflex generator. The cutting usually
leaves burrs on the teeth.

Black Oxide Finish Deburring

The black oxide finish is somewhat Rough spots on the teeth are being
effective in preventing rust. smoothed with a deburring machine.

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(2) Production Processes

( 2 ) - 4
Production Facilities
Shown here is an example of machines and equipment used in gear making.

CNC Rack Grinding Machine (NRG-100)

CNC Dry Cut Gear Hobbing Machine (N60)

CNC Rack Cutting Machine (NR-18S)

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 (2) Production Processes

CNC Gear Grinding Machine (TAG400)

CNC Dry Cut Hobbing Machine (GP130)

CNC Hypoid Grinding Machine (PH-200G)

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Introduction to Gears / November 1, 2006
Head office/factory 332-0022 13-17 Nakacho, Kawaguchi-shi Tel:048(255)4871 FAX:048(256)2269
Osaka office 540-0012 Tanimachi Yuetsukan building,6-22 Tanimachi 5-chome, Chuo-ku, Osaka
TEL:06-6763-0641 FAX:06-6764-7445
Nagoya office 465-0093 Louvre Building, 3-96 Issha, Meito-ku, Nagoya
TEL:052-704-1681 FAX:052-704-1803

URL http://www.khkgears.co.jp/ E-mail kohara@khkgears.co.jp