Our CNC Gear Machining Services
Elevate your machinery’s performance with our Usinage de l'équipement CNC services—where advanced Technologie CNC meets decades of Gear Manufacturing compétence. We deliver high-precision gears (spurs, helicals, bevels, Et plus) avec des tolérances serrées, Matériaux durables, and superior surface finishes, tailored to automotive, aérospatial, et secteurs industriels. Partner with us for cost-effective, on-time gear solutions that keep your operations running smoothly.
What Is CNC Gear Machining?
Usinage de l'équipement CNC 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), Usinage de l'équipement CNC uses pre-programmed Technologie CNC to automate cutting, mise en forme, et finir, ensuring repeatable precision.
À la base, le Gear Machining Process involves removing material from a workpiece (usually metal) to create teeth with specific profiles (Par exemple, involute, cycloidal) et dimensions. 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.
Nos capacités: Ce que nous pouvons livrer
Notre 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 compétences, and supported Gear Types:
| Catégorie de capacité | Détails | Specifications |
| Gear Types | Spurs, helicals, bevels, engrenages, engrenages internes, planetary gears | Module range: 0.5–20 mm; Nombre de dents: 5–200 teeth |
| Workpiece Size | Small precision gears to large industrial gears | Max diameter: 1,200 MM; Max weight: 500 kg |
| Volume de production | Flexible for low-batch prototypes and mass production | Prototypes: 1–50 unités; Production de masse: 10,000–500,000+ units/year |
| Niveau de précision | Ultra-tight control for critical gear performance | Pitch error: ± 0,005 mm; Runout: ± 0,003 mm; ISO accuracy grade: 4–8 (pour ISO 1328) |
| Personnalisation | Tailored to unique designs and industry standards | Supports custom tooth profiles, matériels, 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.
Processus: The CNC Gear Manufacturing Steps
Le 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:
- Conception & Programmation: We start with your 2D/3D CAD model (Par exemple, ÉTAPE, Igies) 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.
- Préparation des matériaux: The chosen material (Par exemple, acier, laiton) is cut into blanks (cylindrical or conical shapes) et traité à la chaleur (si nécessaire) to improve hardness before machining.
- Usinage brutal: 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.
- Usinage final: We use precision tools (Par exemple, gear shapers, broyeurs) 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 Finition de surface (Par exemple, affûtage, lapping) Pour réduire les frictions et porter. We also inspect the gear for dimensional accuracy using tools like gear testers.
Matériels: Suitable for CNC Gear Machining
Usinage de l'équipement CNC relies on materials that balance strength, durabilité, et machinabilité. Voici le Common Gear Materials Nous travaillons avec, along with their Propriétés des matériaux et utilisations idéales:
| Matériel | Dureté (CRH) | Résistance à la traction (MPA) | Propriétés clés | Applications typiques |
| Acier en alliage (4140) | 28–32 (recuit); 50–55 (à la chaleur) | 860–1 000 | Forte résistance, se résistance à l'usure, toughness | Transmissions automobiles, industrial gearboxes |
| Acier inoxydable (304) | 18–22 | 515 | Résistance à la corrosion, hygiene | Food processing machinery, marine gears |
| Laiton (C36000) | 15–20 | 310 | Excellente machinabilité, frottement faible | Small gears for electronics, instrumentation |
| Fonte (GG25) | 180–220 Hb (≈18–22 HRC) | 250 | Faible coût, good damping capacity | Heavy-duty industrial gearboxes, pumps |
| Alliage en titane (TI-6AL-4V) | 30–35 | 900 | Ratio de force / poids élevé, résistance à la corrosion | Aerospace gears, medical equipment |
Notre Sélection des matériaux process involves collaborating with you to match material properties to your gear’s operating conditions (Par exemple, charger, température, environnement)—ensuring long-lasting performance.
Traitement de surface: Enhancing Gear Performance
Gear Surface Treatment is critical for reducing wear, Améliorer la résistance à la corrosion, and extending gear life. Below are our Finition de surface choix, along with their benefits and ideal uses:
| Treatment Methods | Rugosité de surface (Rampe) | Avantages clés | Idéal pour |
| Gear Grinding | 0.4–1.6 μm | Surface ultra lisse; reduces noise and friction | High-precision gears (ISO grade 4–5) for aerospace |
| Carburisant & Éteinte | 1.6–3.2 μm | Augmente la dureté de surface (jusqu'à 60 CRH); core remains tough | Eaux de transmission automobile (high load) |
| Placage de zinc | 0.8–3.2 μm | Résistance à la corrosion; faible coût | Gears for outdoor equipment, electrical machinery |
| Lapping | 0.02–0,1 μm | Finition effet miroir; improves tooth contact accuracy | Precision instrument gears (Par exemple, montres, capteurs) |
| Phosphation | 1.6–6.3 μm | Enhances lubrication; prevents rust | Gears in hydraulic systems, industrial pumps |
Nous adaptons Post-Machining Treatment to your gear’s needs—whether you need corrosion protection for marine gears or noise reduction for automotive gears.
Tolérances: Precision for Reliable Gear Function
Gear Tolerances directly impact performance: even small errors can cause noise, porter, or failure. We maintain strict Contrôle de la tolérance pour répondre aux normes mondiales. Below are our Tolérances de précision for key gear features:
| Gear Feature | Tolerance Levels | Norme de l'industrie (OIN 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 |
Notre Tolérances d'usinage are calibrated to your gear’s ISO accuracy grade—from grade 8 (standard industrial gears) to grade 4 (high-precision aerospace gears).
Avantages: Why Choose CNC Gear Machining?
Usinage de l'équipement CNC offers clear benefits over manual or traditional methods. Voici la clé Advantages of CNC Gear Machining:
- Précision supérieure: Avec Avantages de précision like ISO grade 4 précision, CNC ensures consistent tooth spacing and profile—critical for gears that mesh smoothly. Manual machining often struggles to reach grade 8 or better.
- Avantages des coûts: Pour une production à volume élevé, CNC automates labor-intensive steps (Par exemple, hobbing, mise en forme), reducing labor costs by 30–40% compared to manual methods. It also minimizes material waste (moins que 5%, contre. 15–20% for manual).
- Flexibility for Custom Gears: CNC easily handles custom designs (Par exemple, non-standard tooth profiles, engrenages internes) 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 (Par exemple, usure, material defects) tôt, garantissant 99.9% defect-free production. Manual machining relies on operator judgment, leading to higher error rates.
Faster Lead Times: Les machines CNC fonctionnent 24/7, Couper les délais de plomb de 50% Pour les commandes à volume élevé. Un lot de 1,000 gears takes 1–2 weeks with CNC, contre. 3–4 weeks with manual methods.
Industrie des applications: Where CNC Gears Add Value
Notre CNC Gear Services support diverse Secteurs de l'industrie, addressing unique challenges in each field. Vous trouverez ci-dessous Applications de l'industrie and how we deliver value:
| Industrie | Application Fields | CNC Gear Uses | Les exigences clés satisfaites |
| Automobile | Transmissions, differential systems, véhicule électrique (VE) drivetrains | Grenouet, vitesses hélicoïdales, planetary gears | Volume élevé (100,000+ unités/an); ISO grade 6–7; noise reduction |
| Aérospatial | Moteurs d'avion, landing gear systems, satellite mechanisms | Titanium alloy gears, bevel gears | Matériaux légers; ISO grade 4–5; high temperature resistance |
| Machines industrielles | Systèmes de convoyeur, pompes, compresseurs, wind turbines | Large helical gears, worm gears | Capacité de charge élevée; ISO grade 7–8; résistance à la corrosion |
| Électronique | Small motors (Par exemple, drones, robots), 3D printers | Micro gears (module 0.5–1 mm), brass gears | Miniature size; frottement faible; ISO grade 6–7 |
| Médical | Surgical robots, équipement de diagnostic | Engrenages en acier inoxydable, titanium gears | Biocompatibilité; résistance à la corrosion; ISO grade 5–6 |
Techniques de fabrication: Méthodes avancées que nous utilisons
To deliver top-tier gears, Nous utilisons à la pointe de la technologie Gear Manufacturing Techniques et Machining Techniques. Below are our core methods:
- Fraisage CNC: The most common method for external gears (spurs, helicals). A rotating hob (cutter with spiral teeth) cuts gear teeth as the workpiece spins. Idéal pour la production en grand volume (Par exemple, engrenages automobiles).
- CNC Gear Shaping: Uses a reciprocating cutter (shaper) to create internal or external gears. Better than hobbing for complex shapes (Par exemple, engrenages internes, 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-Axis CNC Usinage: For complex gears (Par exemple, engins coniques, spiral gears). The 5-axis system adjusts the workpiece’s angle in real time, ensuring accurate tooth profiles on all sides.
Câbler EDM (Usinage à décharge électrique): Used for micro gears (module <1 MM) or hard-to-machine materials (Par exemple, titane). Uses electrical sparks to cut teeth without physical contact—ideal for intricate designs.
Études de cas: Histoires de réussite de nos clients
Étude de cas 1: Automotive EV Drivetrain Gears
Défi: Un fabricant de véhicule électrique leader nécessaire 50,000 vitesses hélicoïdales (module 2 MM, ISO grade 6) for their new drivetrain. The gears required low noise, durabilité élevée, and a 4-week lead time—manual machining couldn’t meet the timeline or precision.
Solution: We used CNC hobbing for rough machining and CNC grinding for finishing. We chose alloy steel (4140) traité à la chaleur à 55 CRH, with zinc plating for corrosion resistance. Notre 24/7 production line ran 10 hobbing machines simultaneously.
Résultat: Livré 50,000 gears in 3.5 weeks with 99.95% taux sans défaut. Le client a signalé un 20% reduction in drivetrain noise and a 15% longer gear life compared to their previous supplier.
Étude de cas 2: Aerospace Landing Gear Bevel Gears
Défi: An aerospace company needed 200 titanium alloy bevel gears (ISO grade 4) for aircraft landing gear. The gears required high strength (résistance à la traction >900 MPA) and tight runout tolerance (± 0,003 mm).
Solution: We used 5-axis CNC machining for rough shaping and CNC gear grinding for finishing. We heat-treated the titanium alloy (TI-6AL-4V) à 35 HRC and added a phosphating treatment for lubrication. We inspected each gear with a CNC gear tester.
Résultat: All gears passed FAA certification. The client noted that the gears handled 20% more load than their previous design, sans usure après 1,000 test landings.
Pourquoi nous choisir: Our Strengths as Your CNC Gear Partner
Lorsque vous choisissez notre Usinage de l'équipement CNC services, you get more than a supplier—you get a partner focused on your success. Voici le Reasons to Choose us:
- Compétence & Expérience: Notre équipe a 20+ des années Gear Manufacturing, with engineers certified in ISO 1328 et les normes aérospatiales (AS9100). Nous avons travaillé avec 500+ clients de l'automobile, aérospatial, and industrial sectors.
- Équipement avancé: We operate 30+ Machines CNC (from Gleason and Mitsubishi)—including 5-axis hobbers, gear grinders, and wire EDM machines. Our equipment is calibrated monthly to maintain ISO grade 4 précision.
- Assurance qualité: Notre ISO 9001:2015 and AS9100-certified facility includes in-house gear testers, CMMS, and material labs. Every gear undergoes 3 inspections (pré-masseur, mid-process, final) pour assurer la conformité.
- Flexible Lead Times: We offer rush services for prototypes (aussi vite que 3 jours) and scalable production for high-volume orders. Notre 24/7 production line cuts lead times by 30% contre. concurrents.
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.