Description

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Precision CNC Machined Gears

Custom CNC machined gears are precision power transmission components manufactured to exact engineering drawings. We produce spur gears, helical gears, bevel gears, worm gears, and internal gears designed for high-load gearboxes, automated machinery, and precision drives.

Core Manufacturing Capability:
Machining Processes: 5-axis CNC milling, high-precision CNC turning, gear hobbing, gear shaping, and gear tooth grinding.

Production Scope: Custom geometries from standard involute profiles to non-standard custom tooth forms.

Manufacturing Integration: In-house blank preparation, precision gear cutting, heat treatment management, and strict dimensional verification.

Technical Specifications

Parameter	Capability Range
Material	Alloy Steels (4140, 8620, 4340), Stainless Steel (304, 316, 17-4PH), Aluminum (6061, 7075), Brass, Bronze, Engineering Plastics (POM, PEEK)
Size Range	Outer Diameter: 10 mm to 800 mm; Length/Width up to 600 mm
Tolerance	+/- 0.005 mm to +/- 0.01 mm (feature dependent)
Gear Accuracy	Up to DIN Grade 5-7 (AGMA Q10-Q12) via precision tooth grinding
Surface Roughness	Gear Flanks: Ra 0.4 um to 0.8 um; Bores/Faces: Ra 0.2 um
Processing Range	Module 0.5 to Module 10; Diametral Pitch 2.5 to 48 DP
Equipment & Process	CNC 5-Axis Machining Centers, CNC Gear Hobbing Machines, CNC Gear Shaping Machines, CNC Cylindrical Grinders

Key Features

Dimensional Accuracy: Strict adherence to blueprint geometric dimensioning and tolerancing (GD&T), maintaining critical pitch diameters and bore runout within tight limits.

Tooth Profile Precision: Controlled tooth flank geometry ensuring proper load distribution, minimal backlash, and smooth meshing performance under operational loads.

Batch Repeatability: Automated CNC tool path execution and rigorous in-process probing ensure consistent part dimensions from the first piece to the end of production.

Complex Geometry Support: Multi-axis milling capabilities allow integration of custom keyways, splines, cross-holes, and lightening pockets directly into the gear body.

Surface Integrity: Controlled feeds and speeds prevent micro-cracking and thermal damage during tooth cutting and finishing operations.

Applications

Automotive: Transmission gears, differential components, steering mechanisms, and oil pump drives.

Industrial Equipment: Heavy-duty industrial gearbox assemblies, crane winches, and conveyor drive rollers.

Automation & Robotics: Precision planetary gearboxes, harmonic drive components, and actuator transfer gears.

Medical Devices: Surgical power tool gearheads and diagnostic equipment drive trains.

Aerospace & Defense: Actuation mechanisms, auxiliary gearbox components, and ground support equipment drives.

Materials & Surface Finishes

Material Options
Carbon & Alloy Steels: AISI 1045, 4140, 8620, 16MnCr5 (supplied in pre-hardened or raw state for subsequent carburizing/hardening).

Stainless Steels: AISI 304, 316, 17-4PH (suitable for corrosive environments).

Non-Ferrous Metals: Aluminum 6061-T6, Phosphor Bronze, Aluminum Bronze (ideal for worm gear pairings).

Plastics: Delrin (POM), Nylon, PEEK (low-noise, weight-reduction applications).

Surface Finishes & Heat Treatments
Heat Treatment: Carburizing & Case Hardening (HRC 58-62), Induction Hardening, Through Hardening, Nitriding.

Coatings & Finishes: Black Oxide, Electroless Nickel Plating, Passivation (for stainless steel), Anodizing (for aluminum).

Finishing: Gear tooth grinding and honing for high-load, low-noise applications.

Customization & OEM

Drawing / CAD Files: We accept STEP, IGES, Parasolid, DXF, and PDF drawings. Complete design review and manufacturability feedback provided upon submission.

Custom Dimensions: Full flexibility to machine non-standard bore sizes, custom face widths, modified pressure angles (14.5 deg, 20 deg, 25 deg), and custom helix angles.

Tolerance Requirements: Custom tolerances accommodated down to micron levels for high-precision instrumentation and aerospace requirements.

Material Selection: Engineering consultation available to select optimal material grades based on torque transmission, wear resistance, and operating environment.

Prototype & Mass Production: Flexible setup for single-piece functional prototypes, pilot runs, and scaled volume production.

Quality Control

CMM Inspection: 3D Coordinate Measuring Machines used for full geometric feature verification and profile evaluation.

Dimensional Inspection: Micrometers, bore gauges, pin gauges, and optical comparators for feature-level verification.

Gear Inspection: Specialized gear measuring centers for lead, profile, pitch, and runout evaluation.

Surface Roughness Testing: Contact profilometers verifying flank and journal surface finishes against engineering specifications.

Material Verification: Mill test certificates (MTC) reviewed for chemical composition and mechanical properties prior to machining.

Packaging & Delivery

Protective Packaging: Individual VCI (Volatile Corrosion Inhibitor) bagging and custom foam cavities to protect precision tooth flanks from impact and moisture during transit.

Batch Identification: Clear part-number and heat-lot labeling on individual packages for full material traceability.

Export Packaging: ISPM 15-compliant fumigated wooden crates or reinforced corrugated cartons for international freight.

Lead Time: Prototypes typically ship in 2 to 3 weeks; production batches scheduled per customer release schedules.

FAQ

Q: What is your Minimum Order Quantity (MOQ)?

A: We support flexible batch sizes starting from 1 piece for prototypes up to thousands of units for production runs.

Q: What gear standards can you manufacture to?

A: We machine gears conforming to AGMA, DIN, and ISO standards based on customer drawing specifications.

Q: Can you supply material test reports?

A: Yes, full Material Test Certificates (MTC) and dimensional inspection reports are provided with shipments upon request.

Q: How do you handle heat-treated gears?

A: We perform rough machining, execute heat treatment (such as carburizing or through-hardening), and finish with CNC gear grinding to eliminate thermal distortion.

Q: What file formats are required for quoting?

A: A 2D PDF drawing containing tolerances, surface finishes, and material specifications, accompanied by a 3D CAD model (STEP format preferred).

Q: What are your typical lead times?

A: Prototypes require 2 to 3 weeks. Production orders generally range from 4 to 6 weeks depending on volume and secondary heat treatment requirements.