Our CNC Gear Machining Services

Elevate your machinery’s performance with our CNC -Zahnradbearbeitung services—where advanced CNC -Technologie meets decades of Gear Manufacturing Sachverstand. We deliver high-precision gears (spurs, helicals, bevels, und mehr) mit engen Toleranzen, langlebige Materialien, and superior surface finishes, tailored to automotive, Luft- und Raumfahrt, und Industriesektoren. Partner with us for cost-effective, on-time gear solutions that keep your operations running smoothly.

cnc gear machining
cnc gear machining

What Is CNC Gear Machining?

CNC -Zahnradbearbeitung is a computer-controlled manufacturing process that produces gears—mechanical components with toothed surfaces that transmit torque and motion between machine parts. Unlike manual gear cutting (which relies on operator skill and is prone to inconsistency), CNC -Zahnradbearbeitung uses pre-programmed CNC -Technologie to automate cutting, Gestaltung, und fertig, ensuring repeatable precision.​

Im Kern, Die Gear Machining Process involves removing material from a workpiece (usually metal) to create teeth with specific profiles (Z.B., involute, cycloidal) und Abmessungen. Gear Manufacturing via CNC integrates software (CAD/CAM) and advanced machines to control every step—from tooth spacing to tooth depth—making it ideal for both standard and custom gear designs. Whether for small hobbyist parts or large industrial gears, CNC ensures accuracy that manual methods can’t match.

Unsere Fähigkeiten: Was wir liefern können

Unser CNC Gear Services cover a full range of gear types and project scales, from prototypes to high-volume production. Below is a detailed breakdown of our Machining Capacity, Precision Gear Machining Fähigkeiten, and supported Gear Types:

FähigkeitskategorieDetailsSpecifications​
Gear TypesSpurs, helicals, bevels, Wurmgetriebe, interne Zahnräder, planetary gears​Module range: 0.5–20 mm; Anzahl der Zähne: 5–200 teeth​
Workpiece SizeSmall precision gears to large industrial gears​Max diameter: 1,200 mm; Max weight: 500 kg​
ProduktionsvolumenFlexible for low-batch prototypes and mass production​Prototypen: 1–50 Einheiten; Massenproduktion: 10,000–500,000+ units/year​
PräzisionsniveauUltra-tight control for critical gear performance​Pitch error: ± 0,005 mm; Runout: ± 0,003 mm; ISO accuracy grade: 4–8 (für ISO 1328)
AnpassungTailored to unique designs and industry standards​Supports custom tooth profiles, Materialien, and surface treatments​

No matter your gear needs—whether a single custom bevel gear or 100,000 spur gears for an automotive line—our Capabilities are scaled to meet your timeline and quality goals.

Verfahren: The CNC Gear Manufacturing Steps

Der CNC Gear Machining Process follows a structured sequence to ensure consistent quality and performance. Below is a step-by-step overview of our Gear Manufacturing Steps, from design to finishing:

  1. Design & Programmierung: We start with your 2D/3D CAD model (Z.B., SCHRITT, IGES) and use CAM software to create a CNC program. This program defines key parameters: gear type, module, number of teeth, cutting tool path, and feed rates—all tailored to your gear’s function.​
  1. Materialvorbereitung: The chosen material (Z.B., Stahl, Messing) is cut into blanks (cylindrical or conical shapes) und hitzebehandelt (bei Bedarf) to improve hardness before machining.​
  1. Grobe Bearbeitung: Using CNC hobbing or shaping machines, we remove excess material to create the basic gear shape. For external gears, hobbing is common; for internal gears, shaping works better. This step gets the gear 80–90% close to its final form.​
  1. Bearbeitung abschließen: We use precision tools (Z.B., gear shapers, Schleifstoffe) to refine the teeth. This step corrects small errors from rough machining, ensuring accurate tooth spacing, profile, and surface smoothness.​

Gear Finishing Process: Depending on requirements, we add Oberflächenbearbeitung (Z.B., Schleifen, lapping) Reibung und Verschleiß reduzieren. We also inspect the gear for dimensional accuracy using tools like gear testers.

Materialien: Suitable for CNC Gear Machining

CNC -Zahnradbearbeitung relies on materials that balance strength, Haltbarkeit, und Verwirrbarkeit. Unten sind die Common Gear Materials Wir arbeiten mit, along with their Materialeigenschaften und ideale Verwendungen:

MaterialHärte (HRC)Zugfestigkeit (MPA)SchlüsseleigenschaftenTypische Anwendungen
Legierungsstahl (4140)28–32 (geglüht); 50–55 (hitzebehandelt)860–1.000Hohe Stärke, Resistenz tragen, toughness​Automobilübertragungen, industrial gearboxes​
Edelstahl (304)18–22515Korrosionsbeständigkeit, hygiene​Food processing machinery, marine gears​
Messing (C36000)15–20310Ausgezeichnete Verwirklichung, geringe ReibungSmall gears for electronics, instrumentation​
Gusseisen (GG25)180–220 Hb (≈18–22 HRC)250Niedrige Kosten, good damping capacity​Heavy-duty industrial gearboxes, pumps​
Titanlegierung (Ti-6al-4V)30–35900Hochfestes Verhältnis, KorrosionsbeständigkeitAerospace gears, medical equipment​

Unser Materialauswahl process involves collaborating with you to match material properties to your gear’s operating conditions (Z.B., laden, Temperatur, Umfeld)—ensuring long-lasting performance.

Oberflächenbehandlung: Enhancing Gear Performance

Gear Surface Treatment is critical for reducing wear, Verbesserung der Korrosionsresistenz, and extending gear life. Below are our Oberflächenbearbeitung Optionen, along with their benefits and ideal uses:

Treatment Methods​Oberflächenrauheit (Ra)SchlüsselvorteileIdeal für
Gear Grinding0.4–1.6 μm​Ultra-smooth surface; reduces noise and friction​High-precision gears (ISO grade 4–5) for aerospace​
Kohlensäure & Abschrecken1.6–3.2 μm​Erhöht die Oberflächenhärte (bis zu 60 HRC); core remains tough​Automobilgetriebe (high load)
Zinkbeschichtung0.8–3.2 μm​Korrosionsbeständigkeit; Niedrige KostenGears for outdoor equipment, electrical machinery​
Lapping0.02–0,1 μmMirror-like finish; improves tooth contact accuracy​Precision instrument gears (Z.B., Uhren, Sensoren)
Phosphating1.6–6.3 μm​Enhances lubrication; prevents rust​Gears in hydraulic systems, industrial pumps​

Wir maßgensässig Post-Machining Treatment to your gear’s needs—whether you need corrosion protection for marine gears or noise reduction for automotive gears.

Toleranzen: Precision for Reliable Gear Function

Gear Tolerances directly impact performance: even small errors can cause noise, tragen, or failure. We maintain strict Toleranzkontrolle globale Standards erfüllen. Below are our Präzisionstoleranzen for key gear features:

Gear Feature​Tolerance Levels​Industriestandard (ISO 1328)Impact on Performance​
Pitch Error (Single Tooth)±0.003–±0.01 mm​Grade 4–8​Ensures smooth torque transmission; reduces vibration​
Runout (Radial)±0.002–±0.008 mm​Grade 4–8​Prevents uneven load distribution across teeth​
Tooth Thickness​±0.005–±0.02 mm​Grade 5–9​Maintains proper backlash (gap between meshing teeth)
Helix Angle Error​±0.05°–±0.2°​Grade 5–8​Critical for helical gears; reduces noise and wear​

Unser Bearbeitungstoleranzen are calibrated to your gear’s ISO accuracy grade—from grade 8 (standard industrial gears) to grade 4 (high-precision aerospace gears).

Vorteile: Why Choose CNC Gear Machining?

CNC -Zahnradbearbeitung offers clear benefits over manual or traditional methods. Unten sind der Schlüssel Advantages of CNC Gear Machining:

  • Überlegene Präzision: Mit Präzisionsvorteile like ISO grade 4 Genauigkeit, CNC ensures consistent tooth spacing and profile—critical for gears that mesh smoothly. Manual machining often struggles to reach grade 8 or better.​
  • Kostenvorteile: Für hochvolumige Produktion, CNC automates labor-intensive steps (Z.B., hobbing, Gestaltung), reducing labor costs by 30–40% compared to manual methods. It also minimizes material waste (Weniger als 5%, vs. 15–20% for manual).
  • Flexibility for Custom Gears: CNC easily handles custom designs (Z.B., non-standard tooth profiles, interne Zahnräder) without retooling—ideal for prototypes or niche applications. Manual methods require new tools for each design.​
  • Quality Advantages: CNC uses real-time monitoring to detect errors (Z.B., Werkzeugkleidung, material defects) early, sicherstellen 99.9% defect-free production. Manual machining relies on operator judgment, leading to higher error rates.​

Faster Lead Times: CNC machines run 24/7, Vorlaufzeiten durch schneiden 50% für hochvolumige Bestellungen. Eine Charge von 1,000 gears takes 1–2 weeks with CNC, vs. 3–4 weeks with manual methods.

Anwendungsbranche: Where CNC Gears Add Value

Unser CNC Gear Services support diverse Branchensektoren, addressing unique challenges in each field. Unten sind der Schlüssel Branchenanwendungen and how we deliver value:

IndustrieApplication Fields​CNC Gear Uses​Wichtige Anforderungen erfüllt
AutomobilTransmissions, differential systems, Elektrofahrzeug (Ev) drivetrains​Getriebe ansporn, helikale Zahnräder, planetary gears​Hochvolumen (100,000+ Einheiten/Jahr); ISO grade 6–7; noise reduction​
Luft- und RaumfahrtFlugzeugmotoren, landing gear systems, satellite mechanisms​Titanium alloy gears, bevel gears​Leichte Materialien; ISO grade 4–5; high temperature resistance​
IndustriemaschinerieFördersysteme, Pumps, Kompressoren, wind turbines​Large helical gears, worm gears​Hohe Belastungskapazität; ISO grade 7–8; Korrosionsbeständigkeit
ElektronikSmall motors (Z.B., Drohnen, robots), 3D printers​Micro gears (module 0.5–1 mm), brass gears​Miniature size; geringe Reibung; ISO grade 6–7​
MedizinischSurgical robots, DiagnosegeräteStainless steel gears, titanium gears​Biokompatibilität; Korrosionsbeständigkeit; ISO grade 5–6​

Fertigungstechniken: Fortgeschrittene Methoden, die wir verwenden

To deliver top-tier gears, Wir verwenden hochmoderne Gear Manufacturing Techniques Und Machining Techniques. Below are our core methods:

  • CNC -Hobbing: The most common method for external gears (spurs, helicals). A rotating hob (cutter with spiral teeth) cuts gear teeth as the workpiece spins. Ideal für die Massenproduktion (Z.B., Kfz -Zahnräder).
  • CNC Gear Shaping: Uses a reciprocating cutter (shaper) to create internal or external gears. Better than hobbing for complex shapes (Z.B., interne Zahnräder, gears with shoulders).
  • CNC Gear Grinding: A finishing technique that uses abrasive wheels to refine teeth. Achieves ISO grade 4–5 accuracy and ultra-smooth surfaces—critical for aerospace or precision instruments.​
  • 5-Achse CNC -Bearbeitung: For complex gears (Z.B., Schräggeräte, spiral gears). The 5-axis system adjusts the workpiece’s angle in real time, ensuring accurate tooth profiles on all sides.​

Draht EDM (Elektrische Entladungsbearbeitung): Used for micro gears (module <1 mm) or hard-to-machine materials (Z.B., Titan). Uses electrical sparks to cut teeth without physical contact—ideal for intricate designs.

Fallstudien: Erfolgsgeschichten unserer Kunden

Fallstudie 1: Automotive EV Drivetrain Gears​

Herausforderung: Ein führender EV -Hersteller benötigte 50,000 helikale Zahnräder (module 2 mm, ISO grade 6) for their new drivetrain. The gears required low noise, hohe Haltbarkeit, and a 4-week lead time—manual machining couldn’t meet the timeline or precision.​

Lösung: We used CNC hobbing for rough machining and CNC grinding for finishing. We chose alloy steel (4140) Hitze behandelt zu 55 HRC, with zinc plating for corrosion resistance. Unser 24/7 production line ran 10 hobbing machines simultaneously.​

Ergebnis: Geliefert 50,000 gears in 3.5 weeks with 99.95% fehlerfreie Rate. Der Kunde meldete a 20% reduction in drivetrain noise and a 15% longer gear life compared to their previous supplier.​

Fallstudie 2: Aerospace Landing Gear Bevel Gears​

Herausforderung: An aerospace company needed 200 titanium alloy bevel gears (ISO grade 4) for aircraft landing gear. The gears required high strength (Zugfestigkeit >900 MPA) and tight runout tolerance (± 0,003 mm).

Lösung: We used 5-axis CNC machining for rough shaping and CNC gear grinding for finishing. We heat-treated the titanium alloy (Ti-6al-4V) Zu 35 HRC and added a phosphating treatment for lubrication. We inspected each gear with a CNC gear tester.​

Ergebnis: All gears passed FAA certification. The client noted that the gears handled 20% more load than their previous design, ohne Verschleiß danach 1,000 test landings.

Warum uns wählen?: Our Strengths as Your CNC Gear Partner

Wenn Sie unsere wählen CNC -Zahnradbearbeitung Dienstleistungen, you get more than a supplier—you get a partner focused on your success. Hier sind die Reasons to Choose us:

  • Sachverstand & Erfahrung: Unser Team hat 20+ Jahre in Gear Manufacturing, with engineers certified in ISO 1328 und Luft- und Raumfahrtstandards (AS9100). Wir haben mit gearbeitet 500+ Kunden in der gesamten Automobilanlage, Luft- und Raumfahrt, and industrial sectors.​
  • Fortgeschrittene Ausrüstung: We operate 30+ CNC -Maschinen (from Gleason and Mitsubishi)—including 5-axis hobbers, gear grinders, and wire EDM machines. Our equipment is calibrated monthly to maintain ISO grade 4 Präzision.
  • Qualitätssicherung: Unsere ISO 9001:2015 and AS9100-certified facility includes in-house gear testers, Cmm, and material labs. Every gear undergoes 3 Inspektionen (Vorabbau, mid-process, Finale) Einhaltung der Einhaltung sicherstellen.
  • Flexible Lead Times: We offer rush services for prototypes (so schnell wie 3 Tage) and scalable production for high-volume orders. Unser 24/7 production line cuts lead times by 30% vs. Konkurrenten.

Competitive Advantages: Our in-house material sourcing and waste-reduction processes lower costs by 15–25%. We also offer free design consultations to optimize your gear for performance and cost.

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