Let's know how gear hobbing process is carried out.
Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities.
It is the most widely used gear cutting process for creating spur and helical gears and more gears are cut by hobbing than any other process as it is relatively quick and inexpensive.
A type of skiving that is analogous to the hobbing of external gears can be applied to the cutting of internal gears, which are skived with a rotary cutter (rather than shaped or broached).
Hobbing uses a hobbing machine with two skew spindles, one mounted with a blank workpiece and the other with the hob. The angle between the hob's spindle (axis) and the workpiece's spindle varies, depending on the type of product being produced. For example, if a spur gear is being produced, then the hob is angled equal to the lead angle of the hob; if a helical gear is being produced then the angle must be increased by the same amount as the helix angle of the helical gear.
The two shafts are rotated at a proportional ratio, which determines the number of teeth on the blank; for example, for a single-threaded hob if the gear ratio is 40:1 the hob rotates 40 times to each turn of the blank, which produces 40 teeth in the blank. If the hob has multiple threads the speed ratio must be multiplied by the number of threads on the hob.
The hob is then fed up into the workpiece until the correct tooth depth is obtained. Finally the hob is fed through the workpiece parallel to the blank's axis of rotation.
Often multiple blanks are stacked, then cut in one operation.
For very large gears the blank can be gashed to the rough shape first to make hobbing easier.
Gear hobbing is most popular process used for gear manufacturing.
Many manufacturing firms that maintain museums of how products were produced in times past will have examples of manual gear hobs that helped to produce gears prior to the gears of the 19th century and earlier.
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Along with these completely manual gear hobs will be samples of some of the first semi-automated gear hobs, and finally examples of more recent technology that demonstrates the fully automated process that modern gear hobs use to produce gears today. A few producers of gear hobs also have interesting literature on the history of gear hobs, including details about how modern gear hobs can produce thousands of gears in a single hour.
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