Gear Boxes, Reduction Gears & Gear Cutting 

The Different Types of Gearboxes, Reduction Gears & Gear Cutting

The gearbox is a vital component of machinery employed in many fields. A reduction gear consists mostly of a system of gears that are linked to various components of a wheel. The set of gears spins, transmitting the incoming motion, and that too at high speed.
 

Gear box types:
 

1. Skew Bevel Helical Gearbox

The skew bevel helical gearbox is robust and may be used in a variety of settings due to its one-piece design and ability to support substantial loads. The mechanical advantages of these industrial gearboxes become available once they are installed on the suitable motor shaft output. 
 

2. Bevel Helical Gearbox

There is a set of curved teeth on the cone-shaped surface of this gearbox, just around the rim. To produce rotational motion between shafts that are not parallel, the bevel helical gearbox is employed.
 

3. Coaxial Helical Inline Gearbox

As its name suggests, the coaxial helical gearbox is best used in situations when high levels of power and efficiency are required. Coaxial helical inlet lines are well-known for their high quality and efficiency.
 

4. Helical Gearbox

In terms of size and power consumption, the helical gearbox is quite efficient. Although this machinery has many potential industrial applications, its primary function is to do demanding jobs. 
 

Reduction Gear Types:
 

1. Single reduction Gear 

The reduction ratio of a single gear set is achieved by a pair of gears in a simple design. The reduction gearbox has individual entry points for the propeller shaft and the engine shaft. In addition to the main gear on the propeller shaft, the assembly features a smaller gear known as a pinion, which is turned by the engine's incoming shaft.

2. Double Reduction Gear 

When a high rate of speed is required, a double reduction gear is employed. The pinion in this double-reduction gear set is coupled to the input shaft (combines with a flexible coupling connection). An intermediate gear is linked to the primary reduction gear. A pinion coupled to a low-speed shaft is what makes this first reduction gear work. The reduction gear attached to the propeller shaft is linked to this pinion.
 

Gear Cutting Types:
 

1. Gear Milling 

Here, a form cutter on a milling machine is used to conduct the actual gear cutting. This cutter rotates along an axis to create gear teeth of uniform length and profile. Once a tooth has been cut, the cutter is taken out of the gear blank so it can be rotated to the next position.
 

2. Gear Hobbing 

In the production of Gear Boxes, Reduction Gears & Gear Cutting, the method known as "hobbing" is used because of its speed and convenience. For hobbing gear teeth into blanks, the machine employs a helical cutting tool, or hob. As a result of its efficiency, this method is well suited for mass manufacturing at the medium- to high-level.
 

3. Gear Broaching 

When creating internal gears or splines, broaching is the best method. It's important to utilize the right broaching tool for the job. The versatility of CNC lathes, mills, machining centers, and other turning machinery makes rotary broaching an attractive option for producing gears.
 

4. Gear Grinding 

Gear grinding is another manufacturing method. When working with a gear blank, gear grinding is done to smooth out any rough spots by rubbing away surface material. The excess metal in the gear is removed by rubbing a rough surface against a piece of metal at high speed.

What Are Gears And Gearboxes.
 

There are many different kinds of gears that can be used inside of a gearbox, including but not limited to bevel gears, spiral bevel gears, wormgears, and planetary gears. Rolling element bearings support and rotate the shafts onto which the gears are placed. The gearbox is a mechanical energy converter that decreases the vehicle's velocity while raising the torque.

Simply put, a gearbox is a mechanical component that includes a set of synchronized gears, shafts, bearings (to support and resolve loads), and, in many cases, a flange for mounting a motor.
 

Main Functions of Gearboxes And Reduction Gears
 

1. Get Ratio

Using the gear ratio, one can quantify the interaction between gears of varying sizes and the amount of energy transferred. An important part of gears is circles, and so the circle measurement is the heart of this calculation. The gear ratio is found by measuring the diameter of a circle. If a smaller gear must make two revolutions to spin a larger gear once, the ratio between them is 2:1, and the output speed is reduced by half. Reducers that use a succession of gear pairs to transform RPM into torque are made easier to understand by this illustration. 
 

2. Gear Reducer Torque 

The gear reducer takes in torque, which is a rotational force, and converts it into a different force and speed while maintaining the same amount of power. 

When the number of revolutions per minute (RPM) of a motor is decreased, the torque it produces increases. Gear reducers, either mounted on the base or the shaft, make this possible. 

The ratio between gear teeth determines the amount of torque that can be multiplied or divided. The fundamental principle of a gear box is that the torque can be increased or decreased depending on the ratio of the gear sizes.
 

3. Drive Gear 

Gear drives, often known as drive gears, modify the rotational velocity, torque, or axis of a shaft. They are, at their most fundamental, a small gear attached to the output shaft that turns a larger gear.

 It's impossible to have variable output speed from a constant power source without them. The worm gear set's driven gear is the brass-colored worm wheel.
 

4. Driven Gear 

The output shaft is linked to the driving gear, which then transfers the reduced power to the load. They occur in a variety of shapes, but regardless of the number of gears in a set, they are always the largest. 

Two driving gears (A and D) are each attached to a separate shaft (B and C) in the compound gear train diagram. For both shafts B and C, the driving gear has the same gear ratio.
 

Difference Between Reduction Gears & Gear Cutting
 

Reduction Gear

Reduction gearboxes, also known as speed reducers, are used to lessen the input speed from the motor while increasing the output torque. The apparatus is used to convert the rotations of the basic engine's output shaft into those required to turn the propeller. The reduction gearbox is home to the wheels and pinions with interlocking teeth responsible for transferring power from the drive shaft to the driven shaft at a lower velocity.

To slow the motor's output, it is coupled with a reduction gearbox, which may alternatively be called a torque multiplier or speed reducer. Reduction gearboxes, which are essentially a gear train connecting the motor to the machine, are overly simplistic in design. Since the output gear is larger than the input gear, the output shaft rotates at a slower rate, generating more torque while maintaining the same speed.
 

Gear Cutting

Designers provide cutting technology for gears up to 3 meters in diameter. When complex gears have to be made quickly, this technology is often the preferred method.

Methods for cutting gears include the following:
 

• Broaching: For gears of this size and larger, a spline or vertical broach is used. The teeth form of a gear can be easily made using this. The biggest gears in the world are made with these equipment and cutters. While this method is costly, it allows for the mass production of huge gears.
   
• Hobbing: refers to the practice of using a hob to make cuts, specifically in the case of a tooth. In order to make one complete rotation of a given gear, the hob must be able to form all of the teeth in one revolution. Although this technique shines for medium and large production runs, it is applied for all run sizes.
   
• Milling or Grinding: Milling equipment or a jig grinder is used in this technique. Helical gears can be made with this.
   
• Shaping: Among the available methods for cutting gears, this is among the most practical. A continuous gear rotational cut in the same plane is used to accomplish this.
   

FAQs: Gear Boxes, Reduction Gears & Gear Cutting
 

Q. What are the different types of gearboxes used in industries?

Ans: Here are the types of Industrial gearboxes:

• Helical Gearbox
• Bevel helical gearbox
• Coaxial helical inline
• Worm reduction gearbox
• Planetary gearbox
   

Q. Difference between gearbox and gear drive.

Ans: When referring to the transmission that connects an electric motor to another piece of machinery, the word "gearbox" is used interchangeably. While the gear drive that connects a motor to the machinery are known as speed reducers. The speed reducer's job is to lessen the rotational velocity between the two terminals.
 

Q. What are the main components of Gearboxes and Reduction Gears?

Ans: Flywheel, Collar, Stick Shift, Clutch Disc, Synchronizers, Selector Fork, Clutch Pedal, and Gears are the common components. 
 

Q. How gear cutting works?

Ans: Cutting gears is done on dedicated machines that are incapable of doing anything else.