Numerically Controlled Machines and Robotic Automation to Optimize Precision Gear Processing

Gear production is a fundamental process for many industrial sectors, from automotive and robotics to precision machine tools. Gears are indeed essential components in motion transmission systems, as they allow for the transformation and modulation of power with high efficiency, minimizing energy losses. Their precision and durability can directly affect the performance of industrial machinery, vehicles, and advanced technological devices.

In recent years, the evolution of production technologies has revolutionized the sector with the introduction of innovative processes and machinery, such as numerically controlled machines (CNC) and robotic automation, as well as the use of advanced high-performance materials. Today, gear production is a constantly evolving sector that must be ready to meet the demands of a market increasingly focused on precision, efficiency, and reliability.

Let’s take a closer look at how gears are made and which new technologies are revolutionizing the sector.

How Mechanical Gears Are Made
The production of mechanical gears is a complex process that requires precision, technical expertise, and the use of advanced machinery. The process starts with the selection of the material, which varies depending on the final application: alloy steels, carbon steels, cast iron, or special materials are selected based on factors such as wear resistance, surface hardness, and operating conditions.

The first stage of the production process is forging or casting the raw material to create the initial piece, which roughly takes the shape of the gear. This is followed by a rough machining phase, usually performed using numerically controlled machines or machining centers, to achieve the basic dimensions of the component.

Next, the gear teeth are created through various machining processes, such as milling, slotting, or broaching. The final grinding phase, especially used for high-precision gears, ensures and enhances the precision and quietness of the gear. After the teeth are cut, gears may undergo heat treatments such as carburizing, hardening, or nitriding to increase surface hardness and improve wear resistance. In many cases, the teeth are then ground again to further refine the profile and ensure extremely tight tolerances.

The process ends with quality control, using 3D measurement instruments and tooth profile verification machines to ensure compliance with the required specifications. Some gears may also undergo protective surface treatments, such as phosphating or nickel plating, depending on the operating environment. All these phases are essential and must be carried out with the highest precision to produce gears that meet the stringent standards required by modern industrial sectors.

The Impact of CNC Machines on Gear Production
Numerically controlled (CNC) machines have introduced a revolution in gear production, ensuring unprecedented quality thanks to their ability to operate with high precision. These machines, equipped with advanced software, eliminate many of the issues related to human intervention and provide significant advantages, including:

• High precision: They allow for extremely tight tolerances, essential for critical applications such as automotive transmission systems or high-performance industrial machinery.
• Unique flexibility: CNC machines can be easily programmed to produce different types of gears, from standard toothed wheels to more complex geometries.
• Operational efficiency: The automation integrated into CNC machines optimizes the production flow. The machines can operate continuously for extended periods, increasing overall productivity and reducing operating costs.

Robotics and Automation: The Future of Gear Production
The gear industry is undergoing an epochal transformation through the integration of robotics and automation into production processes. Automated production lines allow for consistent processing and production times, and improve component quality by eliminating errors and waste, significantly impacting productivity and the sustainability of processes. Thanks to collaborative robots (cobots), the interaction between humans and machines has become smoother and safer, allowing operators to focus on higher-value tasks, such as design and process optimization.

Collaborative robots can be programmed to perform various operations, such as loading and unloading CNC machines, quality control, and assembly of complex components. An example of their versatility is the IRB 2600 ABB robot used by Ingranaggi Gandini: compact and with high load capacity, its design has been optimized for key applications such as arc welding, material handling, and machine tending. Additionally, advanced robotics allows for the production of gears with increasingly complex geometries and minimal tolerances, improving the final product performance and expanding customization possibilities based on customer specifications.

Another strategic advantage of automation in gear production is the reduction of operational costs. The use of robotic solutions ensures high production standards even in high-demand situations, providing greater flexibility and scalability of production. Finally, the integration of advanced digital technologies, such as in Industry 4.0, can enable the virtual simulation and optimization of production processes before their implementation, reducing costs and waste while increasing company competitiveness in the global market.

Technological Innovations and Sustainability in the Gear Sector
New technologies not only improve production efficiency but can also contribute to promoting environmental sustainability. In a context where environmental respect has become a priority for the manufacturing sector, companies are investing in advanced solutions to minimize waste, optimize resource consumption, and reduce CO₂ emissions.

One of the most notable innovations is additive manufacturing (metal 3D printing), which allows for the creation of lighter and more durable components with a significant reduction in material waste compared to traditional removal methods. This approach not only lowers production costs but also reduces raw material consumption and energy demand, fostering a more sustainable production cycle.

At the same time, energy-efficient machining using the latest-generation CNC machinery helps optimize machining processes, reducing the environmental impact. Additionally, the use of advanced protective treatments on finished products can improve the durability and resistance of gears, reducing the need for replacements and, consequently, the volume of industrial waste.

Another key element of sustainability in the gear sector is the implementation of digital technologies that optimize the design and lifecycle of components. Thanks to the latest technologies, it’s possible to virtually simulate the performance of a gear before production, reducing design errors and the number of prototypes needed, positively impacting waste and consumption reduction.

All of these innovations are contributing to redefine the concept of industrial production, combining high performance with a more responsible approach to the environment.

Ingranaggi Gandini: Technology at the Service of Precision Gear Production
In an increasingly competitive global market, relying on an experienced partner is crucial. Ingranaggi Gandini has specialized in the production of precision gears for over 50 years and has continuously evolved, investing in research and development of new technologies to offer customers advanced solutions, ensure high-quality standards, and meet the demands of a market increasingly focused on component customization.

The company uses the latest-generation CNC machinery, including high-precision machining centers, grinders, slotters, lathes, and advanced gear cutters, as well as involute testers, 3D machines, roughness testers, precision intermeshing gauges, and gear analyzers, ensuring dimensional and geometric checks with the highest precision.

The integration of advanced design software and digital simulations optimizes the design phase, reducing production times and improving the performance of the finished products. Moreover, the use of protective treatments and state-of-the-art superfinituring for the production of Gandini Race crowns and pinions ensures a longer lifespan for gears, making them suitable for high-stress environments such as automotive, aerospace, and industrial mechanics.

Attention to quality is a distinguishing feature of Ingranaggi Gandini, which follows strict production and control standards. Each gear undergoes quality checks and compliance tests to verify dimensional tolerances, roughness, and durability. This level of precision is especially crucial for sectors that require high-performance components that are reliable and long-lasting, such as the motorcycle racing industry.

Contact us to get more information and discover how we can support your business with innovative and efficient gear supply!

The Importance of an Efficient and Well-Maintained Motorcycle Transmission Kit
The transmission is the heartbeat of every motorcycle, the component that transfers the engine’s power to the rear wheel, converting energy into motion. Carefully selecting and maintaining the transmission kit in optimal condition is crucial for several reasons. First, a high-quality and well-maintained transmission kit ensures smooth and efficient power transfer, reducing energy losses and improving acceleration and top speed. Additionally, a properly lubricated and correctly tensioned chain minimizes the risk of breakage or failure, which could lead to accidents or malfunctions, thus improving safety, especially in difficult conditions. Investing in a good transmission kit and regularly maintaining it is essential to ensure good performance and long-lasting durability for your motorcycle.

To choose the best kit and achieve the maximum in terms of acceleration, top speed, handling, and lifespan, it’s crucial to carefully consider factors such as the gear ratio, type of chain, and materials used in construction, as well as other aspects.

Let’s take a deeper look at the components of a motorcycle transmission kit and the factors you should consider to make the right choice and get the best performance.

Components of a Motorcycle Transmission Kit
The motorcycle transmission kit consists of three fundamental elements:

• Chain: This component physically transfers power from the sprocket to the gear. It is made up of a series of interconnected links, with rollers that engage with the teeth of the sprocket and gear.
• Sprocket: This is the larger toothed wheel attached to the hub of the rear wheel. The number of teeth on the sprocket affects the final gear ratio.
• Gear: The smaller toothed wheel connected to the output shaft of the gearbox. The number of teeth here also contributes to determining the gear ratio.

Materials Used to Make the Chain, Sprocket, and Gear
The materials used for making the chain, sprocket, and gear influence the performance, durability, and cost of the kit. Some of the most commonly used materials include:

• Steel: The most common material, offering a good balance between strength, durability, and price.
• Aluminum: Lighter than steel, reducing the overall weight of the vehicle and improving acceleration. However, it is less resistant to wear.
• Ergal: A high-strength aluminum alloy that provides an excellent combination of lightness and durability, though at a higher cost.

Types of Motorcycle Chains
There are different types of chains, each with specific characteristics:

• Non-sealed chains: These are the most affordable but require frequent lubrication and have a shorter lifespan.
• O-ring chains: These chains retain lubricant inside the links, reducing maintenance and extending durability.
• X-ring chains: These provide better sealing than O-ring chains, reducing friction further and extending the chain’s lifespan.

How the Number of Teeth on the Sprocket and Gear Affects the Gear Ratio
The number and shape of the teeth on the sprocket and gear can significantly influence the transmission smoothness and the lifespan of the components. A greater number of teeth on the sprocket and fewer on the gear result in a shorter gear ratio, ideal for improving acceleration. This is particularly advantageous for twisty roads or track racing.

On the other hand, fewer teeth on the sprocket and more on the gear extend the ratio, favoring a higher top speed. This configuration is perfect for long-distance rides where smoothness and efficiency at high speeds are essential.

Motorcycles require multiple gear ratios because internal combustion engines with spark ignition have a limited operational range, insufficient to cover the full spectrum from start-up to top speed. The transmission also helps keep the engine RPM within an optimal range, improving both efficiency and power at various speeds. As a result, different gear ratios not only affect performance but can also have a significant impact on fuel consumption.

Maintenance Tips and Care: How to Extend the Lifespan of Your Motorcycle Transmission Kit
After choosing the ideal components for your motorcycle, it’s essential to keep them in perfect condition. Proper maintenance will not only extend their lifespan but also ensure safety and optimal performance.
The motorcycle chain requires regular maintenance such as cleaning, lubrication, and tension checks. It’s recommended to clean the chain using specific products that remove dirt without damaging the seals. After cleaning, apply a suitable lubricant to reduce friction and prevent rust formation. Then, check that the tension is correct: a loose chain can cause slipping, while a too-tight chain can wear out quickly.

Both the sprockets and gears also need regular checks to identify signs of wear and ensure they are securely fixed. Excessive deterioration could compromise the power transfer, and in the worst case, cause significant damage. Timely replacement of these components is essential to maintain the safety and performance of the motorcycle.

Gandini Race: Your Ideal Partner for Choosing Sprockets and Gears

Gandini Race, the division of Ingranaggi Gandini specializing in manufacturing motorcycle mechanical components, combines decades of experience in industrial gear production with a passion for the motorcycle industry, with the goal of producing and selling high-quality sprockets and gears made from top-tier materials and processed with state-of-the-art CNC machines. Thanks to advanced technologies and continuous investment in research and development, Gandini ensures the highest standards for all its products, specifically designed to deliver the best performance and longevity.

The extensive research into finding the balance between lightness and performance led Gandini Race to patent the EGO by Gandini sprocket, aimed at the competition world: a revolutionary one-piece sprocket that sets a new benchmark for final transmission in motorcycles, in terms of mass, smoothness, and wear resistance.

If you want to improve your motorcycle’s performance with a high-quality transmission kit, contact us! Our team of experts is available to offer personalized advice and guide you in choosing the ideal components.

Discover the importance of gear grinding for performance and mechanical precision.

Gear grinding is a mechanical machining process aimed at improving the precision and quality of the tooth surfaces of a gear. This process is essential for producing components that meet extremely tight dimensional tolerances and optimal surface finishes—key characteristics to ensure high performance and reliability in various industrial applications.

Grinding is usually performed as the final phase of the gear manufacturing cycle, after operations like gear cutting or milling. Using specific machinery such as grinders, excess material is removed from the teeth with the help of high-precision abrasive wheels. This process allows for ultra-smooth surfaces and can correct any geometric irregularities, improving the profile and pitch of the teeth.

One of the most important aspects of gear grinding is its contribution to improving performance. A ground gear guarantees smoother and quieter operation, reduces friction, and minimizes wear during use. These advantages are particularly important in industries such as automotive, aerospace, and, in general, any industrial sector where the precision and reliability of components are critical.

Let’s take a closer look at what gear grinding is, the main techniques used, and the benefits it offers.

What Is Gear Grinding and What Is It Used For?
As we’ve seen, gear grinding is a mechanical process aimed at improving the surface and dimensional characteristics of the teeth of a gear. This operation is carried out using specialized machines and abrasive wheels with the goal of achieving:

• Reduction of surface roughness to decrease friction.
• Geometric precision to optimize the meshing of gears.
• Elimination of residual defects from previous processes like milling or gear cutting.

Key Components in Gear Grinding Processes
To ensure effectiveness and precision in gear grinding, it is crucial to understand the role of the key components involved in the process, as they can determine the final product quality and operational efficiency.

The abrasive wheel is an indispensable cutting tool for performing grinding operations. Made from abrasive materials, it can have various shapes and sizes, specifically designed to fit the type and characteristics of the gear being ground. The choice of the wheel, in terms of hardness and binder type, is crucial for achieving the desired surface finish and ensuring process efficiency.

In addition to the abrasive wheel, the grinding machine plays an equally important role. These machines, equipped with computer numerical control (CNC) systems, ensure the precise movement of both the wheel and the gear, allowing for extremely tight dimensional tolerances. Gear grinding machines are designed to ensure the rigidity needed to withstand cutting forces and vibrations generated during the process.

Another essential component is the clamping device, which serves to firmly hold the gear during grinding, preventing any movement or vibration that could compromise the process’s precision. It is made from high-resistance materials and is specifically designed to provide stable and precise clamping, adapting to the shape and size of the gear.

The careful selection of these components, together with the experience and expertise of the operators, is crucial for producing high-quality gears capable of meeting the requirements of any application.

Types of Gear Grinding
Grinding operations are classified in various ways, depending on the purpose of the operation and the type of surface desired:

• Generation Grinding: This method uses a worm wheel that replicates the gear cutting process, allowing for the machining of gears with different modules and pressure angles. It is versatile and suitable for mass production.
• Form Grinding: Here, the wheel has a specific profile that matches exactly the space between two gear teeth. It is ideal for custom productions or gears with special profiles.
• Centerless Grinding: Used for machining small-diameter and long-length parts, this technique employs two wheels between which the part is placed and ground without the need for support centers.
• Cylindrical Grinding: Ideal for working on cylindrical or conical surfaces, both internal and external. This operation uses a wheel whose axis of rotation is parallel to the axis of the workpiece.
• Surface Grinding: The axis of the grinding wheel is perpendicular to the work plane. The workpiece remains stationary, allowing for the creation of flat surfaces with a uniform finish, particularly along the edges.
• Plunge Grinding: The axis of the wheel is parallel, but the motion occurs in a radial approach. This technique is used for machining parts with cylindrical or conical geometries.
• Internal Tooth Grinding: Performed on metal components to eliminate any deformations from previous machining processes.
• External Tooth Grinding: The main objective is the finishing of the surface to ensure smooth operation and high reliability of the mechanical system.

Benefits of Gear Grinding
Gear grinding offers numerous benefits to increase the quality and efficiency of mechanical components, including:

• Improvement of mechanical performance: A smoother tooth surface reduces friction, increasing transmission efficiency and reducing energy losses.
• Extended operational lifespan: Precision in tooth shape ensures uniform stress distribution, reducing wear and extending the life of the gears.
• Reduction of noise and vibration: An accurate tooth profile minimizes discontinuities in the contact between teeth, leading to quieter and more stable operation.
• Increased precision: Grinding allows for tight dimensional tolerances, ensuring optimal operation of gears.

Gandini Gears: The Ideal Partner for Gear Grinding
Gandini Gears is capable of performing high-precision gear grinding operations, offering a cutting-edge service thanks to the use of advanced technologies and established experience in the sector. The company is distinguished by its ability to meet the needs of various industrial sectors, providing tailor-made solutions for every application, from automotive to aerospace, and from mechanical to steel industries.

In 2021, it opened a new department dedicated to gear grinding, equipped with state-of-the-art machinery and operated by highly skilled personnel. This investment allows Gandini Gears to offer grinding services for straight gears, helical gears, and splined shafts up to a length of 800 mm, covering modules from 0.5 to 22, optimizing gear performance, improving precision, and extending component lifespan—key elements for reliable and high-performance transmission systems.

Additionally, the production flexibility allows the company to handle both large batches and custom production, making it the ideal partner for clients with diverse needs.

One of the strengths of Gandini Gears is its ability to manage the entire gear production process, from design to manufacturing, all the way to final grinding. This integrated approach allows for reduced delivery times and ensures continuous quality control throughout all phases of production. The company relies on a highly qualified team that is constantly updated on new technologies, guaranteeing high-level technical support for every project.

For more information about our grinding services or to learn how we can enhance the performance of your gears, contact us!

From November 7th to 10th, the 81st edition of EICMA, the world’s most important motorcycle exhibition, will return to Fiera Milano Rho.

EICMA 2024, the International Motorcycle Exhibition, celebrates its 110th anniversary this year with its 81st edition, further solidifying its status as the leading event for the motorcycle world and its enthusiasts.
This year’s motto is clear: “EICMA. Leaving a Mark for 110 Years,” a reference to the long history of the event and its ongoing influence on the industry and fans worldwide. Visitors and industry professionals will be able to discover a wide range of technological innovations, next-generation motorcycles, futuristic concepts, accessories, and the latest developments in motorcycle gears.

Gandini will also be present during the event and will have its team available for meetings with dealers, distributors, and customers interested in the technology behind the Gandini Race brand.

Gandini Race stands out in the sector for its industrial know-how and the design and commercialization of high-performance motorcycle transmission components and spare parts, which are also used in the world’s most famous championships: by the official Yamaha Racing teams in WorldSBK, the Honda Racing team in MotoGP, and the Ducati Racing team in the MotoAmerica Championship.

EICMA 2024 News: The Return of Big Brands and Technological Innovation
This edition is set to be one of the most significant ever, thanks to the impressive return of iconic brands like BMW and Harley-Davidson. Additionally, as every year, exciting exhibitions, competitions, and interactive activities will take place in the MotoLive outdoor area.

If you’d like to learn more and find out the available dates to meet with the Gandini team, feel free to contact us!