CNC Helical Gears | Custom Precision Machining Solutions
CNC helical gears feature angled teeth engineered for gradual tooth engagement, resulting in higher load-bearing capacity, smoother operation, and reduced noise at high rotational speeds compared to spur gears. Applied primarily in heavy-duty gearboxes, industrial automation drives, and precision power transmission assemblies.
Production capabilities combine 5-axis milling, precision hobbing, and profile grinding to machine complex gear geometries from solid bars, forgings, or castings, maintaining strict control over tooth flank alignment, root fillets, and bore concentricity.
Technical Specifications
|
Parameter |
Standard Capability |
High-Precision Grade |
|
Material |
Alloy Steels, Stainless Steels, Bronze, Engineering Plastics |
20CrMnTi, 42CrMo4, 17CrNiMo6, 316L, Delrin |
|
Size Range |
Outer Diameter: 20 mm – 600 mm |
Outer Diameter: Up to 800 mm |
|
Tolerance |
± 0.005 mm |
± 0.002 mm (critical journals/bores) |
|
Accuracy Grade |
DIN 7 / AGMA Q10 |
DIN 4–5 / AGMA Q12 (Ground profiles) |
|
Surface Roughness |
Ra 0.4 um to 1.6 um (Tooth flank) |
Ra 0.1 um to 0.2 um (Superfinished) |
|
Processing Range |
Module 0.5 to Module 10 |
Module 0.2 to Module 16 |
|
Equipment/Process |
CNC Hobbing, 5-Axis Milling, CNC Gear Shaper, Induction Hardening, CNC Gear Grinding |
Key Features
Tooth Profile Accuracy: Controlled involute profiles and helix lead angles minimize transmission error, backlash, and operational vibration under heavy mechanical loads.
Batch Repeatability: Automated CNC hobbing cycles and closed-loop inspection ensure dimensional consistency across production runs from 50 to 10,000 units.
Complex Geometry Integration: Capability to machine integral shafts, stepped hubs, keyways, internal splines, and lightening pockets in minimized setups.
Thermal Distortion Control: Controlled feed rates and flood coolant application prevent micro-structural cracking during heavy material removal prior to heat treatment.
Tight Concentricity: Bore-to-pitch-circle runout held within strict limits to eliminate eccentric loading and premature bearing fatigue.
Applications
Automotive: Transmission gear trains, transfer cases, and electric vehicle reduction gearboxes.
Industrial Equipment: Heavy-duty industrial gearboxes, extrusion drives, and conveyor power trains.
Automation & Robotics: Precision planetary gearboxes, actuator drive assemblies, and multi-axis joint mechanisms.
Aerospace & Defense: Actuation mechanisms, auxiliary power units, and control surface gear trains.
Medical Devices: Surgical robotics gear drives and diagnostic imaging rotation mechanisms.
Materials & Surface Finishes
Alloy & Carbon Steels: 20CrMnTi, 42CrMo, 8620, C45 (supplied with gas carburizing, case hardening, or through-hardening options up to 58-62 HRC).
Stainless Steels: 304, 316, 17-4PH (corrosion-resistant power transmission).
Non-Ferrous Metals: Phosphor bronze (CuSn12), aluminum alloys (7075-T6).
Heat Treatment & Finishes: Induction hardening, nitriding, black oxide, passivation, and precision gear grinding.
Customization & OEM
Drawing / CAD Files: Comprehensive DFM (Design for Manufacturing) review of STEP, IGES, Parasolid, or 2D PDF technical drawings.
Custom Dimensions: Full customization of module, pressure angle (typically 20°), helix angle, face width, and bore configurations.
Tolerance Requirements: Execution of customer-specified ISO/DIN tolerance classes, surface finish grades, and runout parameters.
Material Selection: Certified material sourcing with full mill test reports (MTR) complying with ASTM, DIN, or JIS standards.
Prototype & Mass Production: Rapid machining of prototypes via 5-axis mills followed by dedicated hobbing and grinding lines for volume production.
Quality Control
CMM Inspection: Hexagon Coordinate Measuring Machines for 3D verification of overall dimensions, pitch diameters, and spatial geometry.
Dimensional Inspection: Calibrated micrometers, bore gauges, pin gauges, and optical comparators.
Surface Roughness Testing: Contact profilometers measuring tooth flank and journal Ra parameters.
Material Inspection: Spectrometer material verification and Rockwell/Vickers hardness testing post-heat treatment.
Final Inspection: 100% visual inspection and dimensional sampling executed according to ISO 2859-1 (AQL standards) or client-specific quality control plans.
Packaging & Delivery
Protective Packaging: Individual VCI (Volatile Corrosion Inhibitor) anti-rust bagging and dense foam compartmentalized cartons to protect fragile tooth flanks.
Batch Identification: Laser-etched part numbers, heat lot numbers, and traceable barcode labeling on all packaging units.
Export Packaging: ISPM 15 compliant heat-treated wooden crates or heavy-duty corrugated containers for secure international freight.
Lead Time: Prototypes delivered in 2-3 weeks; production batches scheduled per Kanban, blanket orders, or fixed delivery forecasts.
FAQ
Request a Quote
Submit your technical documentation for engineering review and formal quotation. Ensure the technical package includes:
- Part Drawing / 3D CAD File (STEP format preferred)
- Material Designation & Heat Treatment Specification
- Target Production Quantity (Annual volume & batch size)
- Tolerance Classes & Gear Accuracy Grade (e.g., DIN / AGMA)
- Target Delivery Timeline
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