Knowledge

The production and quality control of gears used in forged gear pumps is a complex and meticulous process, involving multiple stages and strict standards. The following is a detailed elaboration of this process:

I. Forging of Gear Blanks

The forging of gear blanks is the primary step in gear production. Hot die forging or cross wedge rolling technology is adopted for blank manufacturing to ensure that the blanks have high precision, small machining allowances, and good mechanical properties. During the forging process, the forging temperature, pressure, and die accuracy must be strictly controlled to obtain blanks with the required shape and size.

II. Heat Treatment

The forged blanks need to undergo heat treatment to refine the grains, evenly distribute the carbides, and eliminate the internal stresses in the material. Normalizing treatment is often preferred due to its faster cooling rate and higher productivity. The isothermal normalizing process can ensure stable and reliable product quality.

III. Rough Turning

After heat treatment, the blanks need to undergo rough turning to remove excess material and leave a certain allowance for subsequent finish turning. Rough turning can be carried out using either conventional lathes or CNC lathes to ensure processing efficiency and accuracy.

IV. Fine Turning Process

The fine turning process is a crucial step in gear manufacturing. It involves further precision machining of the gear's outer diameter, end face, and tooth surface to ensure that the dimensions precisely meet the drawing requirements. If subsequent grinding is planned, a certain allowance must be reserved. During the fine turning process, it is essential to strictly control the precision and stability of the processing equipment, as well as the selection and sharpening of cutting tools, to achieve a high-quality gear surface.

V. Tooth Surface Machining

The tooth surfaces of gears are usually processed by gear shaping machines or gear hobbing machines. In mass production, to enhance production efficiency, tools that have undergone coating or plating treatments can be used to extend their service life and reduce the frequency of tool changes and sharpening. During tooth surface machining, processing parameters must be strictly controlled to ensure that the tooth surface accuracy and shape accuracy meet the requirements.

VI. Grinding Processing

For gears with high precision requirements, grinding is an effective finishing process. Grinding is mainly used for processing hardened tooth surfaces, which can effectively correct errors from previous processes and achieve high-precision standards, while reducing the surface roughness of the teeth. During the grinding process, grinding parameters, selection of grinding wheels, and grinding paths must be strictly controlled to obtain high-quality gear surfaces.

VII. Quality Control

During the production process of gears, strict quality control is necessary. Advanced inspection equipment such as gear measuring instruments, gear bearing measuring instruments, and gear grinding quality inspection instruments are used to inspect and measure the geometric dimensions, surface quality, and tooth profile accuracy of gears. By conducting real-time monitoring and control of key processing steps, potential quality issues can be promptly identified and corrected to ensure the consistency and stability of gear processing.

In addition, it is necessary to improve the quality management system for gear processing, including quality control plans, process control, and record management, etc. By formulating clear quality control procedures and standards, the gear processing process can be guided and supervised to ensure the traceability and controllability of gear processing quality.

The production and quality control of gears used in forged gear pumps is a process involving multiple links and strict standards. By strictly controlling each production link and adopting advanced detection equipment and technical means, the quality and performance of gears can be ensured to meet the design requirements, providing a strong guarantee for the efficient and reliable operation of gear pumps.

Vigor produces high-precision pump gears through die forging. If you have any questions and demand of product development or to improve your supply chain, please feel free to contact us at info@castings-forging.com