Re-Grinding Gear Hobs vs. Replacing Them: Which Saves More Money?

Although re-grinding is economical, it is not always the correct solution.

Replacement should be considered when the hob shows:

• Broken or chipped teeth
• Deep cracks
• Severe overheating
• Excessive material loss
• Permanent geometry distortion
• Maximum allowable re-grinding limit reached

Continuing to use or re-grind a severely damaged hob can compromise gear accuracy and increase machining costs.

Comparing the Real Cost

Many buyers compare only the purchase price of a new hob versus the cost of re-grinding.

A better approach is to evaluate the total cost of ownership.

Consider:

• Purchase price
• Re-grinding cost
• Machine downtime
• Tool change frequency
• Tool life
• Production volume
• Scrap reduction

In many cases, a quality hob that is re-ground several times delivers a much lower cost per component than repeatedly purchasing lower-quality replacement tools.

The Importance of Buying Quality from the Beginning

The success of any re-grinding program depends largely on the quality of the original cutter.