Gear Hobbing Dry Vs Wet Hobbing Manufacturing Process

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Gear Hobbing,
Dry vs. Wet
i AMTECH OEM m NEWS v 0
Gear hobbing is a manufacturing technique to

cut gear teeth and is one of the fundamental
processes of gear manufacturing. The process
involves the use of a special type of milling
machine, the hob, to progressively cut the gear
teeth into the workpiece. Gear hobbing is a
generating process, ie., the resulting gear tooth
is not the conjugate form of the hob; instead,
the shape is generated by the combined motion
of the workpiece and the hob moving in a
continuous, timed rotation. As this process is
both reasonably accurate and yet inexpensive, it
is used in a wide range of applications, and
particularly in the manufacturing of spur
gears and helical gears.
Traditionally, the gear hobbing process has been

a ‘wet,’ or ‘lubricated’ process, and involves the
use of coolants — to reduce the severity of the
contact processes caused by machining and
friction, to improve tool life and surface finish, to
reduce corrosion, as well as to provide lubricity.
These coolants can be mineral oils, synthetic
cutting fluids, or a mixture of both, and may be
used in the form of liquids, pastes/gels or
aerosol mists.
While coolants are undoubtedly useful in the

machining process, there are several drawbacks
associated with their use. For one, the rising
costs of coolants has made them a significant
part of the manufacturing cost — from less than
3% of the manufacturing cost thirty years ago, to
nearly 17% today. The cost of the hobbing
machine is also higher due to the need to
process and circulate the coolant.
In the case of gear hobbing, the use of a coolant

necessitates an additional wash operation at the
end of the process. In addition, coolants,
especially when used in the aerosol or mist form,
may lead to respiratory irritation, allergic
reactions, and even poisoning and infection
among workers. Lastly, there are rising
environmental concerns about the cost of
disposing used coolants and contaminated chips
safely and economically.
With the disadvantages of using coolants

outweighing the advantages, it was but a matter
of time before the industry began to explore the
possibility of ‘dry’ hobbing, i.e., hobbing without
the use of coolants. The birth of dry hobbing was
supported by a couple of concurrent
developments in technology — advances in CNC
machine technology, the introduction of better
carbide tool materials, and the total redesign of
the dry cutting machines themselves. These
advances enabled the process of dry hobbing via
the development of highly accurate, high speed
cutting machines using carbide cutters, specialty
coatings and ceramic tools.
Dry hobbing necessitates a redesign of the

hobbing machine. Dry hobbing machines require
a main motor capacity that is 1.5 to 2 times
greater than wet hobbing machines, since the
cutting speeds are proportionately faster. Also,
as there is no coolant to carry away the heat
generated during the hobbing process, the
machine design must ensure thermal stability;
this is usually achieved via special internal
ribbing.
The hot chips generated by the hobbing process

must be wicked away quickly and e#ciently so
as to not a!ect the integrity of the gear being
hobbed. The use of steep chutes, air-blowers,
integrated chip conveyors and vibrating panels
underneath the workpiece can help to e#ciently
and quickly remove chips from the work area. In
addition, careful calibration of the machine feed
and motor speed can ensure an optimal chip
thickness that can carry away the heat from the
work area.
Dry hobbing has proven to be faster, more cost

e!ective, and environmentally friendlier than
conventional wet hobbing. These reasons,
together with the ongoing advances in
electronic technology and in newer tools and
coatings, will ensure that dry hobbing will be
increasingly utilized in the years to come.
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 732-972-5400  Contact AmTech

R IATF 16949 - ISO 9001

R TIER 1 & 2 Manufacturing Supplier

Gear hobbing is a manufacturing technique to

Traditionally, the gear hobbing process has been

While coolants are undoubtedly useful in the

In the case of gear hobbing, the use of a coolant

With the disadvantages of using coolants

Dry hobbing necessitates a redesign of the

The hot chips generated by the hobbing process

Dry hobbing has proven to be faster, more cost

START YOUR PROJECT

Precision manufacturing of gears, shafts,

AmTech is an OEM approved Tier I & II

Stamping & Fineblanking

Custom Engineering services

A Special Thank You

Case Study: Redesign To Reduce Production

Gear Train Assembly

Parts Manufacturer Doing Its Part

Transmission Shaft Types

A Special Thank You

©1995 - Present AmTech OEM, All Rights

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