Gear Cutting Machines

Technology that impresses – used gear cutting machines with precision and reliability.

What are gear cutting machines?

A gear cutting machine is a high-precision machine tool specifically designed for the production, machining, and finishing of gear teeth. Its primary goal is to give gears the exact geometry, surface quality, and dimensional accuracy necessary for smooth and efficient operation in transmissions.
Basically, gear cutting machines perform three main tasks.
The first is gear cutting, also known as tooth forming. In this process, the tooth shape is created in the workpiece – typically through methods such as gear hobbing, gear shaping, or broaching. The result is a pre-cut gear that forms the basis for further machining.

In the second phase, finishing, the tooth flanks are ground, honed, or lapped after intermediate heat treatment to achieve maximum precision and optimal smoothness of operation. This finishing process is of central importance, especially in industries such as the automotive industry, mechanical engineering and aerospace, where minimal tolerances and perfect surface quality are required.

In some applications, only milled or slotted gears are used, eliminating the need for heat treatment and final grinding.

Finally, modern gear cutting machines also handle testing and measurement. Integrated measuring systems and correction functions allow for the direct detection and automatic compensation of quality deviations. This ensures consistently high manufacturing quality and maximum process reliability in gear production.

What types of gear cutting machines are there?

There are various types of gear cutting machines, each used for specific processes in the production of gear teeth (e.g., for spur gears or pinion shafts).

Here is an overview of the most important machine types and their typical applications:

Honing machines are used for gear hobbing, a cost-effective method for the production of external gear teeth, such as those found on spur gears or worm gears. This process, in which a worm-shaped hob rotates synchronously with the worktable in the gaps of the gear and removes material down to the tooth root, is characterized by high productivity and is also ideally suited for automation, making it particularly efficient and economical. However, this process is limited if the resulting tooth shape exceeds a certain profile depth. Gears up to module 8 can typically still be gear-milled.

Gear shaping machines are used in the gear shaping process, a manufacturing method for producing gear teeth. In this process, a tool – the shaping head – is guided in a synchronized rolling motion with the workpiece, creating the desired tooth shape. This method is suitable for the production of both internal and external gears. Gear shaping machines are particularly advantageous when space is limited and tooth widths are small.

Gear grinding machines are used for the high-precision finishing of hardened gears and operate according to the continuous grinding process. This process enables the production of extremely accurate tooth profiles with excellent surface finish using dressable, corundum-bonded grinding worms.

Continuous grinding is used particularly in demanding industries such as the automotive and aerospace sectors for high-volume production that requires consistent accuracy. Due to the high productivity, it is not possible to remeasure the parts during the ongoing process; therefore, 100% process reliability is particularly important in this method.

Bevel gear machining machines are specifically designed for the production of conically shaped hypoid and spiral bevel gears, such as those used in axle distribution gearboxes of vehicles. Depending on the requirements, milling or grinding processes are employed. Both methods enable the precise machining of the complex geometries necessary for optimal power transmission and low noise generation in bevel gears.

Gear profile grinding machines are used for the final machining of large gears, starting at a diameter of 1 mm, when the highest precision and surface finish are required. Profile grinding is typically the preferred method for the final machining of gears with a diameter of Ø500 mm and a module of 8 or greater. In this process, each tooth gap is individually machined. Extensive profile modifications are possible to precisely adapt the tooth geometry to the specific application. The largest application areas for these cylindrical gears are shipbuilding and railway engineering, applications in the steel, cement, and mining industries, and wind energy generation.

Gear testing machines play a central role in modern gear manufacturing. They are used in metrology and serve to precisely test the tooth profile, pitch, flank line, and other geometric features of gears.

Applications of Gear Cutting Machines:

Gear cutting machines are used in numerous industries where gears are required for power transmission or motion control. Typicalapplications include:

• Automotive industry: Manufacturing of gears for manual and automatic transmissions, differentials, and steering systems.
• Mechanical and plant engineering: Production of drive and transmission components for machine tools, conveyor technology, and production plants.
• Energy technology: Machining of gears for wind turbines, turbines, and generators.
• Aerospace: Precision gears for engines, controls, and drive systems.
• Precision mechanics and medical technology: Production of small, high-precision gears for instruments, watches, or medical devices.
• Shipbuilding and railway engineering: Manufacturing of large gears for drives, winches, and locomotive transmissions.

Efficient manufacturing starts with the right machine.

At Fleckenstein Machine Tools, discover a wide selection of used gear cutting machines from leading manufacturers such as Gleason-Pfauter, Liebherr, Reishauer, Klingelnberg, Höfler, and Kapp-Niles. Our machines are ideal for precision gear cutting, grinding, shaping, or milling of gears to the highest quality standards – at attractive prices.

As specialists in high-quality used machinery, we offer:

• Used gear hobbing machines, gear shaping machines, gear grinding machines, and more
• Technically inspected machines with reliable performance
• Personal consultation and worldwide shipping

Whether for single-part production or series production – we have the right solution for your needs. Benefit from our decades of experience in the international machine tool trade. Our expert staff is always happy to assist you – contact us today for a personalized consultation and let's find the perfect solution for your production.