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Worm Gear Manufacturing Through Tangential Hobbing

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Worm Gear Manufacturing Through Tangential Hobbing

Abstract 

To meet the needs of a customer producing reducer worm wheels (1:5 to 1:70 ratio), Nimble Machines introduced a CNC-based tangential hobbing solution using a taper hob on its VAJRA Gear Hobbing Machine. This enhanced both production efficiency and gear quality, reaffirming Nimble Machines as a solution-focused partner in precision gear manufacturing.

Background

Nimble Machines, a business vertical of UCAM Pvt Ltd, designs and manufactures high-precision CNC gear hobbing machines for the global gear manufacturing industry. Focused on innovation and performance, its machines feature direct drive technology, automation compatibility, dry/wet hobbing, and support for advanced processes like gear skiving—making them ideal for high-efficiency, high-accuracy production across sectors.

The Customer

A leading industrial gearbox manufacturer serving sectors like renewable energy, mining, and heavy industry, the client is known for high-precision worm gearboxes. To meet demanding quality standards, they adopted CNC gear hobbing technology, enabling:

  • Consistent dimensional accuracy

  • Superior surface finish for longer gear life

  • Reduced cycle times and increased output

This shift enhanced their manufacturing efficiency and reinforced their position as a technology-driven industry leader.

The Challenge

The customer’s old conventional machines led to:

  • Inconsistent worm wheel profiles

  • Long cycle times and low throughput

  • High manual intervention and finishing costs

Additionally, their worm wheels had high lead angles, requiring a machine with tangential hobbing capability using taper hobs to achieve the needed accuracy and surface finish.

The Solution: Tangential Hobbing with Taper Hob on VAJRA

Nimble Machines provided the VAJRA Gear Hobbing Nimble Machines provided the VAJRA Gear Hobbing Machine featuring:

  • Tangential hobbing with a taper hob for precise machining of worm wheels with high lead angles, preventing profile distortion

  • A specialized indexing formula to synchronize hob spindle and work table rotation accurately

  • Custom CNC macros developed for quick setup, consistent quality, and process stability

This tailored tangential hobbing solution perfectly addressed the application’s complexity.

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