What is Gear Cutting?

Gear cutting is any machining process for creating a gear. The most common gear cutting processes include hobbing, broaching, milling and grinding. Such cutting operations may occur either after or instead of forming processes such as forging, extruding, investment casting, or sand casting.

Gear cutting services include design, manufacture, assembly of gearboxes and maintenance.

Types of Gear Cutting

There are many different types of gear cutting including:

  • Spurs
  • Bevel
  • Helical
  • Moulded
  • Racks
  • Worm and worm wheels
  • Internal gears

Gear Cutting

How do we Use Gears?

Gears are used in many machines. Many are machines we use in our everyday life, such as cars, clocks, bikes, vacuums etc. Gears make our lives easier in many ways.  Gears can increase or decrease the speed of rotation and can easily be used to reverse the direction of rotation. Another reason gear is essential is that they transmit rotational motion to a different axis.

Process of Gear Cutting

There are many different processes involved in gear cutting along with types of machines to be used to define different types of gears. The various production methods for producing gears by machining are as follows.

Hobbing is a machining process for gear cutting, cutting splines and cutting sprockets on a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the workpiece by a series of cuts made by a cutting tool called a hob.

Broaching is a machining method in which a series of cutting teeth each remove a portion of stock as the cutting tool moves past or through the workpiece. Combining both roughing and finishing in one operation. Broaching removes stock to precise tolerance faster than any other known metal cutting process.

Milling is the most common form of machining, a material removal process, which can create a variety of features on a part by cutting away the unwanted material.

Grinding is a material removal and surface generation process used to shape and finish components such as gears. Grinding is used instead of or as well as milling, to achieve better precision and surface finish.

Gear Cutting

Gears are commonly made out of metal, plastic, and wood, however mainly metal and are custom made for many different businesses.

Gear cutting services are available for many different industries such as automotive, food, packing, plastics, dairy, mining, quarrying and many different others.

Coded welding is the process of completing a welder approval test in a certain type of welding configuration. Some of the codes are more general but some are very specific to the job in hand.

The UK uses welder approval codes done to BS EN standards; the USA uses the ASME IX standard. A welding specification is provided for the job which needs to be completed. The welder will then provide a welding sample which mirrors the job as closely as possible.

If the welder passes, then they are coded to that specification. Each different specification requires further training to become a multi-coded welder.

There are many different types of welding used in industry today. TIG is commonly used when high quality, clean welds are needed for the product. MIG is the most common welding process used in industry where parts need to be welded quickly and cover various materials. MMA or stick welding is a low-cost technique and extremely versatile as it can be used in all positions. Fusion welding is commonly used to join polyethylene pipes using heat and copper wire, these are used in the gas & water industry.

Once the welds are complete, they then need to be tested. As with welding, testing must be done to certain standards with NDT (Non-Destructive) testing being the most common. The inspection is usually carried out on 5% of the weld. There are other testing methods available these include VT Testing (Visual Inspection), MT Testing (Magnetic Particle Inspection), PT Testing (Liquid Penetrant Inspection) and X-Ray (Radiographic Inspection).


The Application and Features of Eddy Current Systems

Investing in the latest technology and machinery to help with the recycling of metal and scrap metal is incredibly beneficial for not only us but the surrounding environment. The role of the eddy current systems in the recycling industry is a simple yet effective one which requires the latest, top of the range eddy current systems to perform effectively and efficiently.

But how do eddy current systems work? The purpose of the eddy current systems is to identify and remove all non-ferrous metals from the waste that come from recycled shredded material. The system uses a rotating drum with magnets to recover non-ferrous metals while everything non-metal is left unaffected, making eddy current systems perfect for the isolation of different types of metal separated from one another.  This drum rotates at high speeds to form an electrical current which has the ability to separate the non-ferrous metals from the process stream.

Eddy Current Systems Metal Separation

Key Features of The Eddy Current System

Eddy current systems are widely used and trusted throughout many industries because of the essential feature they incorporate to provide the most effective metal separation. One of these features include eddy current system being available in different configuration options. This is so the eddy current systems are set to achieve maximum separation capabilities for project at hand.

In addition, another key features of eddy current systems are the utilization of rare earth magnets. These magnets in eddy current systems provide the repelling force needed for the separation of metallic materials from non-metallic material to provide a cleaner high quality product. Rare earth magnets enable eddy current systems the capability of separating domestic and industrial waste into two individual containers, separating non-ferrous metals such as aluminium and copper from non-metallic materials such as wood and plastics.

These essential features and the industrial applications the eddy current systems possess have made them crucial equipment for the separation of ferrous and non-ferrous metal across a variety of industries.

Industrial Applications Include:

– Aluminium can recovery

– Material recovery facilities

– Wood recycling

– Electronics and WEEE recycling

– Glass recycling

– Fridge recycling

– Incinerator bottom ash

– Fragmentiser plant / Auto scrap


The art of forging dates back to at least 4000BC aging the process to over 6000 years old! It is one of the oldest metalworking processes and involves the shaping of metal using compressive forces – usually a hammer (mainly a power hammer) or die (tool) is used. Forging is often categorised depending on the temperature used – there’s cold forging, warm forging and hot forging. For the warm and hot forging, the metal is heated in a forge.


There are several types of hot forging as well, which include Drop Forging, Upset Forging and Hand Forging.

Drop Forging :

The process of compressing the pre-heated material between two dies. Usually a hammer is raised and then ‘dropped’ onto a heated piece of metal to reshape it. There are two types of drop forging – open-die and closed-die. The advantages of drop forging consist of greater strength and improved microstructure.

Upset Forging :

one of the most commonly used methods and can also be known as ‘heading’. It is mainly used to form bolt heads and screw heads etc. However, some materials will then need to have drop forging to, for example, punch the hole out of an eyebolt.

Most forging is done manually, especially Hand Forging, also known as blacksmithing, where the work is performed by hand, by highly skilled staff. The metal is initially heated to red heat and then beaten into shape on a metal anvil. The end result are products that are stronger and much more durable.

Forging can be very dangerous and must be done with deep care and consideration. Some workers experience joint pain, risk to sight/hearing and burns.

Most forging companies are family run and have been in the family for generations, which many companies are extremely proud of.

In recent times, technological advances have led to potentially using computer-controlled hammers in the future.