How it's Made: Regular Worm Gears vs EasternGear’s Globoid Worm Gears


In the world of manufacturing, precision and efficiency are critical in producing high-quality components. For worm gears, two types often come into play: regular (cylindrical) worm gears and globoid worm gears. Both serve crucial roles in various industrial applications, but their manufacturing processes differ significantly. This blog explores how regular worm gears and globoid worm gears are manufactured using Mazak Integrex CNC machines, highlighting the differences and advantages of each approach.

Understanding Worm Gears: Regular vs. Globoid

Worm gears are a type of gear arrangement in which a worm (resembling a screw) meshes with a worm wheel (a gear). They are commonly used for their ability to provide high reduction ratios and transmit torque efficiently in a compact space.


Regular (Cylindrical) Worm Gears: In this configuration, the worm has a cylindrical shape with helical threads, while the worm wheel has a disc-like shape with helical teeth cut into its surface. The worm's helical threads mesh with the helical teeth of the worm wheel, allowing for smooth engagement and efficient torque transmission. This design is relatively straightforward to machine and is commonly used in various applications.

Globoid Worm Gears: Unlike regular worm gears, globoid worm gears have a curved or globoid shape, allowing for better meshing and load distribution. The unique geometry enhances efficiency, torque capacity, and wear resistance, but also requires more precision in manufacturing.

Manufacturing Processes: Regular vs. Globoid Worm Gears

Manufacturing Regular Worm Gear Sets

Regular worm gears are typically manufactured using conventional methods such as hobbing or thread grinding. The process generally involves:


1. Gear Blank Preparation: The gear blank (the initial form of the gear) is machined into a cylindrical shape.
2. Hobbing and Thread Grinding: The gear teeth are cut using a hobbing machine or a thread grinder. These processes are well-suited for cylindrical shapes, allowing for quick and efficient gear production.
3. Heat Treatment: After machining, the gears undergo heat treatment to enhance hardness and durability.
4. Finishing: The final finishing processes, such as polishing or coating, ensure the gear meets the required surface finish and tolerances.
https://www.youtube.com/watch?v=XZgsV0AZJJ0

Manufacturing Globoid Worm Gears


1. EasternGear's Manufacturing Process: Using Mazak's Integrex 5-axis CNC machine.

Globoid worm gears, due to their unique geometry, require a more complex manufacturing process. This is where the capabilities of Mazak Integrex CNC machines come into play.

  • Precision Machining: Globoid worm gears are manufactured using Mazak Integrex machines, which are known for their multi-tasking capabilities. The Integrex series combines turning, milling, drilling, and grinding in a single setup, ensuring high accuracy and consistency.


  • Multi-Axis Capabilities: The Integrex machines offer 5-axis simultaneous machining, which is essential for creating the complex contours of globoid worm gears. This capability allows for precise machining of the curved surfaces, ensuring tight tolerances and optimal gear meshing.


  • Automation and Software Integration: Mazak Integrex machines use advanced software and automation to optimize the machining process, reducing setup times and minimizing errors. The integration of CAD/CAM software ensures that the gear’s complex geometry is precisely replicated from design to production.


  • Post-Processing: At EasternGear, we also use hardened steel (SCM 440) or bronze, chosen for their strength and wear resistance for our double-enveloping worm gear sets without the need for heat treatment**, preserving material integrity and dimensional accuracy. We also do not require any additional deburring or polishing, however, if the customer requests to have these done, we are also capable of doing so. 

 **Why EasternGear Chooses to Avoid Heat Treatment**

While many manufacturers still apply heat treatment even after precise 5-axis machining, EasternGear has chosen a different path. We avoid heat treatment due to its potential downsides, such as distortion, surface oxidation, residual stresses, increased brittleness, and added costs. By focusing on precision machining using our advanced Mazak Integrex machines, we maintain tight tolerances and material integrity without the need for heat treatment, delivering high-quality, durable components efficiently and sustainably.

 

The Role of Mazak Integrex CNC Machines

The advanced multi-tasking capabilities of the Integrex machines are particularly suited for the complex geometry of globoid worm gears. These machines can handle intricate shapes and tight tolerances, crucial for achieving the high degree of accuracy required for optimal meshing and performance. The ability to perform various operations, like contouring, drilling, and finishing, in one setup significantly reduces production time and costs.

Advantages of Using Mazak Integrex Machines for Worm Gear Manufacturing

  • Improved Precision and Quality: The multi-axis capabilities and high accuracy of Mazak Integrex machines ensure the correct tooth profiles and smooth operation of both regular and globoid worm gears.
  • Reduced Lead Times: By consolidating multiple processes into one setup, Integrex machines minimize setup times and manual handling, leading to faster production cycles.
  • Flexibility and Customization: With their advanced software and automation, Integrex machines can quickly switch between different gear types and sizes, offering greater flexibility in production.
  • Cost Efficiency: Reduced waste, lower tooling costs, and minimized manual intervention contribute to lower overall production costs.

Case Study: EasternGear's Experience with Mazak Integrex Machines

At EasternGear, we've seen firsthand the benefits of using Mazak Integrex machines for worm gear production. Our adoption of the Integrex series has enabled us to achieve unparalleled precision in our globoid worm gears, resulting in a 30% reduction in production time and a significant improvement in gear performance and durability.

 

Can Anyone Manufacture Precision Gears with a 5-Axis Machine?

Does owning a 5-axis machine automatically guarantee high-quality gear manufacturing?

The short answer? No.

The long answer: While 5-axis machines offer advanced capabilities, their effectiveness depends on proper usage and expertise. Just as having an advanced editing program doesn’t guarantee great results without skillful use, a 5-axis machine alone doesn’t ensure top-quality production. Expertise in design, manufacturing conditions, and a deep understanding of the machine’s capabilities are crucial for achieving the best outcomes.

Manufacturing complex components, such as globoid worm gears, requires not only advanced equipment but also precise calculations and tailored design approaches. Each variable, such as gear size and tooth count, impacts the final product and demands careful consideration.

3D Design and Expertise Matter

https://www.zakgear.com/Wormoid.html 

Effective use of 5-axis machining technology involves a comprehensive process from design to final production. 3D modeling and simulation are essential for designing complex gears. This process allows for accurate simulations of gear teeth contact surfaces before any material is cut, enabling rapid adjustments and minimizing errors.

 Conclusion

In summary, while traditional worm gear manufacturing involves multiple distinct stages, our approach to globoid worm gears integrates all necessary processes into a single, streamlined workflow. This not only enhances precision and efficiency but also ensures the highest quality and durability of our products.

At EasternGear, we leverage advanced 5-axis technology and deep manufacturing expertise to deliver top-quality, durable gear solutions efficiently and sustainably.


Interested in learning more about how EasternGear can provide custom worm gear solutions for your applications? Contact us today!

 

 

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