How do I ensure that my custom gear cutters are made properly?
When it comes to ordering standard or custom gear cutters, S&D Precision Toolmakers are your perfect partner.
Here’s a general process for ordering gear cutters:
1. Contact Us
Provide us with the details of the required Gear Cutter. Type (MAAG, Sunderland or Fellows), Pitch, Pressure Angle, as well as any other required specifications e.g. Rougher, Finisher, Protuberance, Sprocket, Spline etc.
2. Quotation and Design
We will provide you with a Quotation that includes an approval Drawing showing the Cutter Design and Dimensions.
Once you are satisfied with the cutter design and Quotation, forward us a signed copy of the Approval Drawing with your Purchase Order.
Once your approval is received, the manufacturing process can begin. We hold pre-machined, hardened and Ground ASP2030, ASP2060 and ASP2023 High Speed Steel in Stock, ready for Cutter manufacture.
5. Quality Control
Quality control measures are implemented throughout the production process to ensure that the gear cutters meet the specified tolerances and quality standards.
Once the gear cutters are manufactured and pass quality control checks, they are packaged and delivered to your specified location.
How do you manufacture my parts from sample?
Manufacturing parts from a sample involves the process of reverse engineering, where you create a new part by analyzing and replicating an existing part, often without access to the original design or specifications. This can be a valuable approach when you need to reproduce or replace a component for which you have no documentation or when you want to improve an existing design. Here’s a general process for manufacturing parts from a sample:
1. Sample Analysis
Carefully examine the existing part to understand its shape, dimensions, and functionality. Take detailed measurements using calipers, micrometers, CMM Inspection and other precision measuring tools.
Document any unique features, material properties, surface finishes, and tolerances that are critical for the new part’s performance.
2. Material Selection
Determine the material used in the original part, if possible. If not, choose a suitable material based on the part’s function and expected operating conditions.
3. CAD Modeling
Create a three-dimensional computer-aided design (CAD) model of the part. The CAD model should match the dimensions and geometry of the sample.
4. Manufacturing Process Selection
Choose the appropriate manufacturing method for producing the part. Common methods include machining (CNC milling, turning, etc.), 3D printing, casting, forging, or fabrication.
5. Manufacturing the Part
Use the CAD model to guide the manufacturing process. Precision machining processes, such as CNC milling and turning, wirecutting and Grinding are often used when high accuracy and tight tolerances are required.
6. Quality Control
Implement quality control measures throughout the manufacturing process to ensure the new part meets the desired specifications. This may involve inspections, measurements, and testing.
Maintain detailed records of the manufacturing process, including CAD files, specifications, and quality control data. This documentation is valuable for future reference and potential revisions.
Manufacturing parts from a sample can be a complex process that requires expertise in various fields, including engineering, materials science, and manufacturing technology. Collaboration with our experienced engineers and manufacturers will ensure a successful outcome.
What is a ‘job shop’?
A ‘job shop’ is a type of manufacturing business or workshop that specialises in producing custom or made-to-order products based on the specific requirements of individual customers. In a job shop, the production process is typically flexible and adaptable, allowing for a wide variety of products to be manufactured, often in relatively small quantities or one-off orders.
Key characteristics of a job shop include:
Job shops focus on producing products that are tailored to the unique needs and specifications of each customer. This often involves a high degree of customization, where no two orders may be exactly the same.
2. Varied Production
Job shops may produce a wide range of products or components, often spanning multiple industries. These products can include machined parts, tooling, dies, jigs, prototypes, and other specialized items.
3. Low to Medium Volume
While job shops can handle both small and larger production runs, they typically excel at low to medium production volumes. They are well-suited for producing limited quantities of specialized items.
Job shops must be adaptable and flexible in terms of equipment, processes, and workforce to accommodate diverse customer requirements. They often invest in versatile machinery that can handle various tasks.
5. Skilled Workforce
Job shops employ skilled machinists, toolmakers, and technicians who can operate and program machinery, work with various materials, and handle complex machining and manufacturing tasks.
6. Quick Turnaround
Job shops aim for efficient turnaround times to meet customer deadlines. They are known for their ability to handle urgent or rush orders.
7. Diverse Industries
Job shops may serve a wide range of industries, including aerospace, automotive, defense, medical, electronics, and more. Their versatility makes them valuable to various sectors.
8. Quality Control
Maintaining quality standards is crucial for job shops. They often have quality control processes and inspections in place to ensure that each custom product meets the specified tolerances and requirements.
9. Prototyping and Development
Job shops are often involved in the prototyping and development phases of new products, helping customers refine their designs and create prototypes before full-scale production.
10. Cost Estimation
Due to the customised nature of their work, job shops typically provide cost estimates based on the specific project requirements, materials, labour, and other factors.
Job shops play a vital role in the manufacturing ecosystem by offering a flexible and adaptable solution for companies that need specialised or unique components, parts, or products.
Their ability to provide custom manufacturing services helps businesses meet their diverse and changing needs without the need for extensive in-house production capabilities.