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Gearbox Repair

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Gear Cutting

Gear cutting is the process of creating a gear. The most common processes include hobbing, broaching, and machining; other processes include shaping, forging, extruding, casting, and powder coating and heat treating, flame hardening carburizing and lapping.

Broaching 
For very large gears or splines, a vertical broach is used. It consists of a vertical rail that carries a single tooth cutter formed to create the tooth shape. A rotary table and a Y axis are the customary axes available.

Some machines will cut to a depth on the Y axis and index the rotary table automatically. The largest gears are produced on these machines.

Other operations such as broaching work particularly well for cutting teeth on the inside. The downside to this is that it is expensive and different broaches are required to make different sized gears. Therefore it is mostly used in very high production runs.

Hobbing 
Hobbing is a method by which a hob is used to cut teeth into a blank. The cutter and gear blank are rotated at the same time to transfer the profile of the hob onto the gear blank. The hob must make one revolution to create each tooth of the gear. Used very often for all sizes of production runs, but works best for medium to high.

Machining 
Gears are cut or ground on a milling machine and gear cutter utilizing a numbered gear cutter, and any indexing head or rotary table. The number of the gear cutter is determined by the tooth count of the gear to be cut. 
To machine a helical gear on a manual machine, a true indexing fixture must be used. Indexing fixtures can disengage the drive worm, and be attached via an external gear train to the machine table’s handle (like a power feed). It then operates similarly to a carriage on a lathe. As the table moves on the X axis, the fixture will rotate in a fixed ratio with the table. The indexing fixture itself receives its name from the original purpose of the tool: moving the table in precise, fixed increments. If the indexing worm is not disengaged from the table, one can move the table in a highly controlled fashion via the indexing plate to produce linear movement of great precision (such as a Vernier scale). 
There are a few different types of gear hobs and cutters used when creating gears. One is a rack shaper. These are straight and move in a direction tangent to the gear, while the gear is fixed. They have six to twelve teeth and eventually have to be moved back to the starting point to begin another cut. Some other types of gear hobs we utilize are; helical cutting, planetary gear cutting, herringbone gear cutting, spiral bevel gear cutting, straight tooth gear cutting and spline cutting. 
A popular way to build gears is by form cutting. This is done by taking a blank gear and rotating a cutter, with the desired tooth pattern, around its periphery. This ensures that the gear will fit when the operation is finished.

Shaping
The old method of gear cutting is mounting a gear blank in a shaper and using a tool shaped in the profile of the tooth to be cut. This method also works for cutting internal splines. 
Another is a pinion-shaped cutter that is used in a gear shaper machine. It is basically when a cutter that looks similar to a gear cuts a gear blank. The cutter and the blank must have a rotating axis parallel to each other. This process works well for low and high speed gears.

Finishing
After being cut the gear can be finished by shaving, burnishing, grinding, honing or lapping. With this method of refinishing, we can also leave a high mirror finish or a reground finish and get gears within “0” tolerance.

Grinding
Grinding is a process of finishing the surface of tool so as to make it use for various operations. Abrasive materials are used for grinding a gear when it needs to be ground and carburized, such as surface grinding, lapping grinding, internal and external grinding, blanch grinding and all other types of grinding. 
There is no need for your company to go back to OEM and pay 100% of the purchase price when we can rebuild and recondition this equipment. We are looking forward to hearing from you.

Spray Metalizing

Metalizing is a sprayed process of building up worn areas on all types of machinery parts. In traverse hardening systems the work piece is passed through the induction coal progressively and a following quench spray or ring utilized. Traverse hardening is used extensively in the production of shafts, drive shafts, trunnion rolls, excavator bucket pins and all other types of rotating equipment. The component is fed through a ring type inductor which normally features a single turn. The width of the turn is dictated by traverse speed, the available power and frequency of the generator. This creates a moving band of heat which when quenched creates the hardened surface layer. Therefore, we can provide longer life and longer wear on equipment with this technology.

By varying speed and power it is possible to create a shaft which is hardened along its whole length or just in specific areas and also to harden with steps in diameter or splines. It is normal when hardening round shafts to rotate the part during the process to ensure any variations due to concentricity of the coil and the component removed.

All types of rotating welding metalizing, heat treating and flame hardening. For more information give us a call. There is no need for your company to go back to OEM and pay 100% of the purchase price when we can rebuild and recondition this equipment. We are looking forward to hearing from you.

Metal Hardening

Heat treating is a process of Induction Hardening is a form of heat treatment in which a metal part is heated by induction heating and then quenched. Also case hardening available Selective hardening heat treating processes that harden only one area of a part also may mean a physical barrier is applied to prevent carburization and hardening of an area of the part.

Temper processing is a way that you reduce the hardness out of worn out equipment that has been hardened age hardening, anneal for machining, full anneal, regular temper, stress relieve and temper anneal.

Flame hardening perfect results for challenging work pieces. Our range of hardening machines, together with customized coils and patented multi-frequency technology can handle the trickiest hardening tasks.

Nitriding is a surface-hardening heat treatment that you apply after maching or grinding a surface that introduces nitrogen into the surface of steel at a temperature range (500 to 550 C, or 930 to 1020F), while it is in the ferrite condition. Thus, nitriding is similar to carburizing in that surface composition is altered, but different in that nitrogen is added into ferrite instead of austenite. Because nitriding does not involve heating into the austenite phase field and a subsequent quench to form martensite, nitriding can be accomplished with a minimum of distortion and with excellent dimensional control. Principal reasons for nitriding: To obtain high surface hardness, to increase wear resistance, to improve fatigue life, to improve corrosion resistance, to obtain a surface that is resistant to the softening effect of heat at temperatures up to the nitriding temperature.

Hardening procedures

Electro less Nickel

Titanium Nitride

Chrome Plating

Boron Coating

Nicarb Coating

Thermo Fusion

Stellite 12

Electro Hard Facing

Nickel Plating

All Types of rotating welding metalizing, heat treating and flame hardening. For more information give us a call. There is no need for your company to go back to OEM and pay 100% of the purchase price when we can rebuild and recondition this equipment. We are looking forward to hearing from you.

Machinery Repair

Hanson Gear Works has a state of the art style of rebuilding and refurbishing. We Specialize in rebuilding all types of ball Screws and Nuts, Spindle Arc Chucks, spline Shafts Ball Splines head stock Rebuilding Brass Nut repair, Re-threading and re-cutting on feed screws Heat Exchanger. All types of Pumps, all types of Gear and Gearbox repair, Gear Cutting and Gear Hobbing, all types of Moyno Shafts, all types of Dies for Stamping industry, all types of Rams for the Pressing, also feed screws for meat processing plants, Electric Motors of all makes and model, Blower, Crank Shafts, and Piston, Shafts, re-cutting of Splines, Keyway Cutting, and also all types of cutting equipment, Broaches, and all other types of equipment, don’t discard expensive machine parts.

Our company rebuilds worn and broken equipment regardless of make model and manufacturer. Equipment though irreparable of even scrap can usually be returned to manufacturers specs and tolerances.

We have the facilities to rebuild and recondition them back to O.E.M. standard. Why pay 100% to the manufacturer when we can rebuild and extend the life of your equipment and save you up to 50% over many years, we have developed the experience and expertise needed to repair and refurbish machinery with O. D. – I. D. Grinding, Gear Hobbing, CNC Equipment.

All Types of rotating welding metalizing, heat treating and flame hardening. For more information give us a call. There is no need for your company to go back to OEM and pay 100% of the purchase price when we can rebuild and recondition this equipment. We are looking forward to hearing from you.

Contact: (713)799-1900

Canada (587) 200-8555

Email: info@hansoncearworks.com

Locations: Houston, TXCharlotte, NC

© Hanson Gear Works 2019

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