Precision cutting, shaping, milling and grinding of a wide variety of gears
Our precision gear cutting service is aimed at businesses large and small and our skilled engineers are experienced in working on a wide variety of gear types. No matter how simple or how complex the job, you can be assured of first class work and rapid service from the team at Westin Engineering.
Creating bespoke components – or reverse engineering new parts from old ones or drawings – is part of our daily work. Our customers come from across the spectrum of industries, among them textiles, mining and quarries, chemical, oil and gas, water, power generation and food and drink. SPUR GEARS These are a common gear type and among the most cost effective methods of gearing. Generally they have straight teeth and transmit motion and power between parallel shafts. HELICAL GEARS The teeth of these gears are set at an angle. Helical are similar to spur gears except the teeth are cut at an angle to the axis. They typically engage more slowly and smoothly than other types of gears used for similar applications, because the load is transferred uniformly and gradually. |
INTERNAL GEARS
Also known as ring gears, these are similar to external spur gears except the teeth are cut into the inside diameter while the outside remains smooth. Internal gears can bring speed reductions and reduced sliding wear and can be used in a wide range of applications. BEVEL GEARS We custom manufacture high quality bevel gears for many industries, from small to large, in a variety of materials and size ranges. WORMS and WORM WHEELS We create custom engineered and standard worms for particular gearing applications. We can make single or multiple start worms with right or left hand threads and/or multiple leads. RACK and PINION Our experienced engineers can produce rack and pinion mechanisms for most applications. Rack and pinion gearing converts rotational motion into linear motion. Rack and pinion mechanisms are commonly found in steering systems, actuators and printing equipment. |
Our gear cutting services
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The range of gears we cut
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Gears and gear teeth exist in infinite varieties, so it’s difficult to cover all eventualities. So if you have any questions about gear manufacturing or precision engineering, please speak to one of our friendly team.
CASE STUDY: Manufacturing a wheel and pinion
1. The process begins on the lathe, where the steel (EN36) is turned down to a precise size to allow for grinding where required on the two parts. This means that when the parts come back from hardening, they can be ground between centres.
2. The keyways are then milled into the pinion using our Bridgeport miller or XYZ millers.
3. The pinion is then set up and cut on our David Brown hobber (for helical gears) or on one of our Jowett’s (for spur gears). For this job, it was on the David Brown. Meanwhile, the wheel is set up and cut on the Sunderland gear planer which does both helical and spur gears. In this process we cut to given or calculated sizes and allow for grinding. We are one of the few companies that still dress gears by hand, giving them a better appearance and fewer sharp corners.
4. After the pinion has come back from hardening, it is ground between centres on our Churchill OD and Bore grinder. The wheel is bore ground on the Churchill grinder and then face ground, making sure the face is true to the bore. The other face is then ground on our various surface grinders. Finally, the pinion is set up between centres on the Niles gear grinder and ground.
5. The gear and pinion go through several hands during this process, so accuracy at each stage is vital. Our skilled, experienced engineers ensure the job is successfully completed to the highest quality and ready to be securely packed and sent to the customer.
– Liam Medley
1. The process begins on the lathe, where the steel (EN36) is turned down to a precise size to allow for grinding where required on the two parts. This means that when the parts come back from hardening, they can be ground between centres.
2. The keyways are then milled into the pinion using our Bridgeport miller or XYZ millers.
3. The pinion is then set up and cut on our David Brown hobber (for helical gears) or on one of our Jowett’s (for spur gears). For this job, it was on the David Brown. Meanwhile, the wheel is set up and cut on the Sunderland gear planer which does both helical and spur gears. In this process we cut to given or calculated sizes and allow for grinding. We are one of the few companies that still dress gears by hand, giving them a better appearance and fewer sharp corners.
4. After the pinion has come back from hardening, it is ground between centres on our Churchill OD and Bore grinder. The wheel is bore ground on the Churchill grinder and then face ground, making sure the face is true to the bore. The other face is then ground on our various surface grinders. Finally, the pinion is set up between centres on the Niles gear grinder and ground.
5. The gear and pinion go through several hands during this process, so accuracy at each stage is vital. Our skilled, experienced engineers ensure the job is successfully completed to the highest quality and ready to be securely packed and sent to the customer.
– Liam Medley
CASE STUDY: Manufacturing a Worm Wheel Set
1. The process begins with the worm shaft, which is turned and milled in the service section of Westin Engineering.
2. The worm is then cut using our Lees Brander worm cutter on which we can cut single start or multiple start worms. In this specific case study it was a two start worm and a 41 tooth wheel. Once cut, the worm is sent to hardening.
3. We next turn the wheel, which involves turning the cast iron hub and then turning the phosporus bronze ring. We then sweat the ring on to the cast iron hub and weld them together, ensuring the bronze ring isn’t able to move or spin.
4. The wheel is then set on our Pfauter gear hobber, on which we make bespoke tools to cut the correct angle and depth into the wheel, forming the teeth.
5. When the worm comes back from hardening it is OD ground between centres to tight tolerances. It is then worm ground on our Matrix 46 worm grinder.
6. Finally, the worm and the wheel are paired on a Goulders tester to simulate the centres of the gearbox, confirming we have the correct backlash and ensuring smooth running between the two.
– Liam Medley
1. The process begins with the worm shaft, which is turned and milled in the service section of Westin Engineering.
2. The worm is then cut using our Lees Brander worm cutter on which we can cut single start or multiple start worms. In this specific case study it was a two start worm and a 41 tooth wheel. Once cut, the worm is sent to hardening.
3. We next turn the wheel, which involves turning the cast iron hub and then turning the phosporus bronze ring. We then sweat the ring on to the cast iron hub and weld them together, ensuring the bronze ring isn’t able to move or spin.
4. The wheel is then set on our Pfauter gear hobber, on which we make bespoke tools to cut the correct angle and depth into the wheel, forming the teeth.
5. When the worm comes back from hardening it is OD ground between centres to tight tolerances. It is then worm ground on our Matrix 46 worm grinder.
6. Finally, the worm and the wheel are paired on a Goulders tester to simulate the centres of the gearbox, confirming we have the correct backlash and ensuring smooth running between the two.
– Liam Medley