Gear grinding is a technique used in gear making where unwanted materials are removed through an abrasion process. It is usually the last step in the gear-making process and involves using a grinding machine to remove the last bits of metal off the gear. Gear grinding can also refer to mis-shifting a manual transmission vehicle, which causes the gears to make a loud grinding noise. This is usually caused by releasing the clutch when the car is not fully in the new gear, causing the gears to rub against each other without engaging.
Gear grinding is the name of a specific gear making technique. Grinding involves the removal of unwanted materials through an abrasion process. Grinding is typically the last step in the gear-making process; other techniques removed most of the material first. There are several grinding methods, but not all of them are used for creating gears. In addition to the meaning of gear making, gear grinding is the common term for mis-shifting a manual transmission vehicle.
Gears are made using a variety of methods. In general, rough cuts are made from a piece of metal that creates the overall shape of the gear. The gear then moves on to a more precise machine that removes more material; this process can be repeated several times. Eventually, the gear enters its final stage, which is almost always a grinding machine.
Grinders work by abrasion. They rub a rough surface against a workpiece at such high speeds that they literally scrape unwanted material off the object. Because the grinder spins so fast, material is removed very quickly. This allows a grinder to pick up a very small amount without carrying around unwanted material.
In general, grinding systems work in two ways. Either the workpiece is held still and the grinding surface moves, or the surface is stationary and the workpiece moves. In gear grinding, it is usually the former. Most gear grinders hold the gear stationary while a workhead moves around the gear. This head contains a high precision abrasive plate which grinds the last bits of metal off the gear.
The final polish on the gear is usually done in a grinder as well. The same machine that removes material can also polish and smooth the finalized gear. Instead of a grindstone, the machine employs a polishing wheel; the process is the same as grinding, except that no material is removed. The final grinding and polishing tasks are usually the last two stages in gear manufacturing.
Gear grinding in a car is usually caused by a timing error between the clutch and gearbox. When the driver depresses the clutch, he disengages the car’s gears. At that time, there were no direct connections between the engine and the car’s drive system. The driver then shifts the car into the new gear, which will change to the physical gear used when the driver releases the clutch. When the driver releases, the gears are reengaged and the car continues in a different gear.
Failure in this sequence will cause the car’s gears to make a loud grinding noise. The most common mistake is releasing the clutch when the car is not fully in the new gear. When the car tries to hang onto the gear, it is between two different gears. This causes the gears to rub against each other, but not engage, thus making the common grinding noise.
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