Description

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Custom-machined and precision-ground helical gears manufactured directly from customer CAD/2D technical drawings. Engineered for high-load, high-speed power transmission requiring low transmission error, controlled backlash (<= 0.05 mm nominal), and reduced acoustic signature compared to spur equivalents.

Volume Flexibility: Prototype lot size 1-5 pcs (3-4 weeks); production lot size flexible from 10 to 5,000 pcs/year.

Trade/Compliance Scope: Commercial industrial grade (Non-ITAR standard export tier; customs/ISPM15 full packet included).

Technical Specifications

Parameter	Standard Capability	High-Precision Tier	Test Method / Standard
Accuracy Grade	DIN 7 / AGMA Q10	DIN 4-5 / AGMA Q12-Q14	Klingelnberg P-Series Gear Tester
Module Range (m)	m1.5 - m16	m1.0 - m12	Micrometer / Gear tooth caliper
Max. Outer Diameter	<= 800 mm	<= 500 mm	Coordinate Measuring Machine (CMM)
Face Width	<= 250 mm	<= 180 mm	Vernier / Depth micrometer
Pressure Angle (alpha)	20 deg (standard), 14.5 deg	Custom angle on request	Optical comparator
Helix Angle (beta)	Up to 45 deg (left/right)	Up to 30 deg (ground flank)	Gear analytical center
Surface Hardness	HRC 58 - 62 (carburized)	HRC 59 - 61 (controlled case depth)	Vickers/Rockwell tester
Case Depth (CHD)	0.8 - 2.5 mm	0.6 - 1.8 mm	Metallographic cross-section

Key Features

Continuous Overlap Ratio (overlap beta > 1.2): Gradual tooth engagement lowers impulse excitation and mesh frequency spikes.

Flank Grind Finish: Ra 0.4 - 0.8 um profile/lead grind eliminates hobbing/shaping ripple, suppressing micro-pitting initiation.

Distortion-Controlled Heat Treatment: Controlled atmosphere vacuum carburizing paired with multi-point quench fixture press reduces tooth-to-tooth pitch accumulation error post-hardening.

Root Fillet Optimization: Undercut-free root contour generated via profile-shifted hobbing/grinding to raise bending fatigue limit (sigma_FE per ISO 6336).

Applications

Industrial Gearboxes: Helical reduction stages in extruder drives and heavy cement mill gear units.

Robotics & Actuators: Second-stage high-torque reduction in heavy industrial articulated robotic arms.

Renewable Energy: Pitch and yaw drive gear trains in wind turbines.

Test Benches: Dynamometer drive gearboxes requiring zero-backlash configuration.

Customization Envelope & DFM Loop

Input Data Required: 2D drawing (PDF/DXF with GD&T, datum references, heat treatment spec, flank tolerance chart) + 3D STEP.

DFM Feedback Protocol: Engineering review delivered within 24 working hours covering undercut risk, grind wheel runout clearance, and distortion risk mitigation.

Material Options:
20CrMnTi (GB), 8620H (AISI), 18CrNiMo7-6 (DIN) for case-hardened high-torque duty.
42CrMo4 / 4140 for through-hardened medium-load service (HB 280-320).

Surface Treatments: Manganese phosphate, gas nitriding, DLC coating upon request.

ID / Spline Finishes: Broached, wire-EDM splines, or internal ground spline bores (DIN 5480 / ANSI B92.1).

Quality Control & Inspection

Gear Analytical Inspection: 100% first-article profile, helix, pitch, and runout inspection chart provided via gear tester.

Metallurgy Verification: Batch coupon testing for core/surface micro-hardness gradient, grain size (ASTM E112 >= 6), and retained austenite check (<= 20% via X-ray/metallography).

NDT: 100% magnetic particle inspection (MPI / MT) per ASTM E1444 for subsurface grinding crack detection.

Manufacturing & Certifications

Machining Assets: Gleason / Liebherr CNC hobbers, Reischauer and Höfler continuous/profile gear grinders.

Heat Treatment: In-house multi-purpose chamber furnaces with carbon potential IR control (%C +/- 0.05%).

Quality System: ISO 9001:2015 certified; IATF 16949 compliant process control for automotive/industrial tier accounts.

Traceability: Heat number stamped on face/hub; material mill test reports (MTR EN 10204 3.1) linked to shipping documentation.

Packaging & Delivery

Corrosion Protection: VCI (Volatile Corrosion Inhibitor) film wrapping vacuum-sealed + de-moisturizing packet.

Physical Protection: Individual high-density PE foam or wooden edge-spacer cradles; export-compliant heat-treated ISPM 15 wooden crates.

Shipping Terms & Risk Mitigation: FOB / CIF / DDP. Full customs documentation package provided; trade compliance/commercial export status verified per project scope.

FAQ

Q: Can you grind gears from a rough-machined/hobbed blank supplied by us?

A: Yes, provided datum faces (bore/face runout <= 0.015 mm) and stock allowance for grinding (0.15 - 0.30 mm per flank) are verified.

Q: What is your standard lead time for a 10-piece custom helical gear order requiring profile grinding?

A: 4 to 5 weeks from technical drawing sign-off and material readiness.

Q: Do you issue measurement protocols with every production shipment?

A: Standard delivery includes dimensional inspection report; full AGMA/DIN analytical gear measurement plot available upon PO specification.

Q: How do you handle heat-treatment lead error compensation?

A: Helix modification (lead crowning and pressure angle modification) is pre-computed in CAD via CNC grinding profile correction software based on empirical material growth curves.

Q: How do you handle non-conformance?

A: 8D report provided within 48 hours; free remake or credit memo for dimensional/metallurgical deviation from agreed print spec.