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Remanufacturing: Step by step Some of the parameters which must be defined prior to starting manufacturing are: Pitch: There are several systems of defining the pitch of a gear, including Diametral, Circular and Module, with variations of each such as stub tooth, full depth, extended profile and others. Pressure Angle: This can be something common like 14½ or 20 degrees, something less common like 25 degrees or even something completely non-standard. Note: Manufacturers will often design parts with uncommon pitch or pressure angle when they originally produce them. This will make it difficult for the owner of such a gear to obtain a replacement part from economic sources. This forces the owner of the part to go back to the original manufacturer for the replacement. Some manufacturers will take advantage of this by charging exorbitant prices or requiring unnecessary replacement of entire systems rather than individual components. When the OEM produced such a product it would have been economical to purchase special tooling for cutting the teeth to non-standard dimensions. But when the end-user needs to buy a replacement he only needs one or two pieces. Most local gear shops have limited tooling inventories and will not have anything that would typically be classified as non-standard in the industry. Gear tooth cutting tools are very expensive and time consuming to produce. This situation tightens the hold an OEM has on an end-user for supply of replacement parts. We have a large inventory of gear cutting tools and the ability to make our own tools in some cases. This allows us to produce some of the specially designed gears that many companies would not be able to manufacture. If we cannot cut the gear to its original specifications we may work with the end-user to establish a very similar configuration using common tooling. In this case all the gears mating together as a set would have to be replaced, but this may still be more economical than some other options. Helix angle, lead angle, spiral angle, shaft angle, tooth and span measurements, standard and operating pitch diameters, center distance and mounting distance: This array of angles and measurements apply to various types of gears. They are determined using specialized precision measuring instruments and mathematical calculations. Other physical dimensions: length through bore, face length, hub diameter, bore size, keyway and setscrew, bolt hole circles, bearing fits, et. al. These dimensions must be properly defined to ensure a proper fit with equipment in the field. After all the technical data have been collected a CAD drawing and description of the manufacturing process are developed and submitted to manufacturing personnel. A note about materials: We utilize a wide range of carbon, alloy and stainless steels as well as other materials (including bronze, aluminum, nylon, phenolic, and others) in the manufacture of products. We have selected particular grades as standard stocking materials. These particular grades have been selected for a variety of reasons such as availability, cost, and good overall mechanical properties. When we evaluate a sample submitted for remanufacturing we will evaluate it visually and measure its hardness. Then we will select the material we carry as a standard stocking material that provides the best fit to the original part and suggest it for the replacement part. We do not normally analyze materials to identify specific chemical compositions. This can be done if necessary, but incurs additional cost. Special materials can be obtained as well, also at additional cost and lead-time. |