Our CNC Gear Machining Services
Elevate your machinery’s performance with our Lavorazione di ingranaggi CNC services—where advanced Tecnologia CNC meets decades of Gear Manufacturing competenza. We deliver high-precision gears (spurs, helicals, bevels, e altro) con tolleranze strette, Materiali durevoli, and superior surface finishes, tailored to automotive, aerospaziale, e settori industriali. Partner with us for cost-effective, on-time gear solutions that keep your operations running smoothly.
What Is CNC Gear Machining?
Lavorazione di ingranaggi 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), Lavorazione di ingranaggi CNC uses pre-programmed Tecnologia CNC to automate cutting, modellando, e finire, ensuring repeatable precision.
Al centro, IL Gear Machining Process involves removing material from a workpiece (usually metal) to create teeth with specific profiles (PER ESEMPIO., involute, cycloidal) e dimensioni. 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.
Le nostre capacità: Cosa possiamo offrire
Nostro 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 competenze, and supported Gear Types:
| Categoria di capacità | Dettagli | Specifications |
| Gear Types | Spurs, helicals, bevels, ingranaggi a vite senza fine, ingranaggi interni, planetary gears | Module range: 0.5–20 mm; Numero di denti: 5–200 teeth |
| Workpiece Size | Small precision gears to large industrial gears | Max diameter: 1,200 mm; Max weight: 500 kg |
| Volume di produzione | Flexible for low-batch prototypes and mass production | Prototipi: 1–50 unità; Produzione di massa: 10,000–500,000+ units/year |
| Livello di precisione | Ultra-tight control for critical gear performance | Pitch error: ± 0,005 mm; Runout: ± 0,003 mm; ISO accuracy grade: 4–8 (per ISO 1328) |
| Personalizzazione | Tailored to unique designs and industry standards | Supports custom tooth profiles, Materiali, 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.
Processo: The CNC Gear Manufacturing Steps
IL 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:
- Progetto & Programmazione: We start with your 2D/3D CAD model (PER ESEMPIO., FARE UN PASSO, 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.
- Preparazione del materiale: The chosen material (PER ESEMPIO., acciaio, ottone) is cut into blanks (cylindrical or conical shapes) e trattati con calore (se necessario) to improve hardness before machining.
- Macchinatura ruvida: 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.
- Finitura di lavorazione: We use precision tools (PER ESEMPIO., gear shapers, smerigliatrici) 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 Finitura superficiale (PER ESEMPIO., macinazione, lapping) per ridurre l'attrito e indossare. We also inspect the gear for dimensional accuracy using tools like gear testers.
Materiali: Suitable for CNC Gear Machining
Lavorazione di ingranaggi CNC relies on materials that balance strength, durata, e macchinabilità. Di seguito sono riportati il Common Gear Materials Lavoriamo con, along with their Proprietà materiali e usi ideali:
| Materiale | Durezza (HRC) | Resistenza alla trazione (MPA) | Proprietà chiave | Applicazioni tipiche |
| Acciaio in lega (4140) | 28–32 (ricotto); 50–55 (trattato con calore) | 860–1.000 | Alta resistenza, resistenza all'usura, toughness | Trasmissioni automobilistiche, industrial gearboxes |
| Acciaio inossidabile (304) | 18–22 | 515 | Resistenza alla corrosione, hygiene | Food processing machinery, marine gears |
| Ottone (C36000) | 15–20 | 310 | Eccellente macchinabilità, basso attrito | Small gears for electronics, instrumentation |
| Ghisa (GG25) | 180–220 hb (≈18–22 HRC) | 250 | Basso costo, good damping capacity | Heavy-duty industrial gearboxes, pumps |
| Lega di titanio (Ti-6al-4v) | 30–35 | 900 | Rapporto elevato di forza-peso, Resistenza alla corrosione | Aerospace gears, medical equipment |
Nostro Selezione del materiale process involves collaborating with you to match material properties to your gear’s operating conditions (PER ESEMPIO., carico, temperatura, ambiente)—ensuring long-lasting performance.
Trattamento superficiale: Enhancing Gear Performance
Gear Surface Treatment is critical for reducing wear, Migliorare la resistenza alla corrosione, and extending gear life. Below are our Finitura superficiale opzioni, along with their benefits and ideal uses:
| Treatment Methods | Rugosità superficiale (Ra) | Vantaggi chiave | Ideale per |
| Gear Grinding | 0.4–1.6 μm | Ultra-smooth surface; reduces noise and friction | High-precision gears (ISO grade 4–5) for aerospace |
| Carburazione & Spegnimento | 1.6–3.2 μm | Aumenta la durezza superficiale (fino a 60 HRC); core remains tough | Ingranaggi di trasmissione automobilistica (high load) |
| Zinco | 0.8–3.2 μm | Resistenza alla corrosione; basso costo | Gears for outdoor equipment, electrical machinery |
| Lapping | 0.02–0,1 μm | Mirror-like finish; improves tooth contact accuracy | Precision instrument gears (PER ESEMPIO., orologi, sensori) |
| Fosfating | 1.6–6.3 μm | Enhances lubrication; prevents rust | Gears in hydraulic systems, industrial pumps |
Facciamo personalizzare Post-Machining Treatment to your gear’s needs—whether you need corrosion protection for marine gears or noise reduction for automotive gears.
Tolleranze: Precision for Reliable Gear Function
Gear Tolerances directly impact performance: even small errors can cause noise, Indossare, or failure. We maintain strict Controllo della tolleranza Per soddisfare gli standard globali. Below are our Tolleranze di precisione for key gear features:
| Gear Feature | Tolerance Levels | Standard di settore (Iso 1328) | Impact on Performance |
| Pitch Error (Single Tooth) | ±0.003–±0.01 mm | Grade 4–8 | Ensures smooth torque transmission; reduces vibration |
| Runout (Radiale) | ±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 |
Nostro Tolleranze di lavorazione are calibrated to your gear’s ISO accuracy grade—from grade 8 (standard industrial gears) to grade 4 (high-precision aerospace gears).
Vantaggi: Why Choose CNC Gear Machining?
Lavorazione di ingranaggi CNC offers clear benefits over manual or traditional methods. Di seguito sono riportati la chiave Advantages of CNC Gear Machining:
- Precisione superiore: Con Vantaggi di precisione like ISO grade 4 precisione, CNC ensures consistent tooth spacing and profile—critical for gears that mesh smoothly. Manual machining often struggles to reach grade 8 or better.
- Vantaggi dei costi: Per la produzione ad alto volume, CNC automates labor-intensive steps (PER ESEMPIO., hobbing, modellando), reducing labor costs by 30–40% compared to manual methods. It also minimizes material waste (meno di 5%, contro. 15–20% for manual).
- Flexibility for Custom Gears: CNC easily handles custom designs (PER ESEMPIO., non-standard tooth profiles, ingranaggi interni) 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 (PER ESEMPIO., abbigliamento per utensili, material defects) early, garantire 99.9% defect-free production. Manual machining relies on operator judgment, leading to higher error rates.
Faster Lead Times: Le macchine CNC funzionano 24/7, tagliare i tempi di consegna da 50% Per ordini ad alto volume. Un lotto di 1,000 gears takes 1–2 weeks with CNC, contro. 3–4 weeks with manual methods.
Industria delle applicazioni: Where CNC Gears Add Value
Nostro CNC Gear Services support diverse Settori del settore, addressing unique challenges in each field. Di seguito sono fondamentali Applicazioni del settore and how we deliver value:
| Industria | Application Fields | CNC Gear Uses | Requisiti chiave soddisfatti |
| Automobile | Transmissions, differential systems, veicolo elettrico (EV) drivetrains | Ingranaggi speroni, ingranaggi elicoidali, planetary gears | Volume elevato (100,000+ unità/anno); ISO grade 6–7; noise reduction |
| Aerospaziale | Motori dell'aeromobile, landing gear systems, satellite mechanisms | Titanium alloy gears, bevel gears | Materiali leggeri; ISO grade 4–5; high temperature resistance |
| Macchinari industriali | Sistemi di trasporto, pompe, compressori, wind turbines | Large helical gears, worm gears | Alta capacità di carico; ISO grade 7–8; Resistenza alla corrosione |
| Elettronica | Small motors (PER ESEMPIO., droni, robots), 3D printers | Micro gears (module 0.5–1 mm), brass gears | Miniature size; basso attrito; ISO grade 6–7 |
| Medico | Surgical robots, apparecchiatura diagnostica | Stainless steel gears, titanium gears | Biocompatibilità; Resistenza alla corrosione; ISO grade 5–6 |
Tecniche di produzione: Metodi avanzati che utilizziamo
To deliver top-tier gears, Usiamo all'avanguardia Gear Manufacturing Techniques E Machining Techniques. Below are our core methods:
- Dentatura CNC: The most common method for external gears (spurs, helicals). A rotating hob (cutter with spiral teeth) cuts gear teeth as the workpiece spins. Ideal for high-volume production (PER ESEMPIO., ingranaggi automobilistici).
- CNC Gear Shaping: Uses a reciprocating cutter (shaper) to create internal or external gears. Better than hobbing for complex shapes (PER ESEMPIO., ingranaggi interni, 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-Asse Machining CNC: For complex gears (PER ESEMPIO., ingranaggi smussati, spiral gears). The 5-axis system adjusts the workpiece’s angle in real time, ensuring accurate tooth profiles on all sides.
EDM di filo (Lavorazione a scarica elettrica): Used for micro gears (module <1 mm) or hard-to-machine materials (PER ESEMPIO., titanio). Uses electrical sparks to cut teeth without physical contact—ideal for intricate designs.
Casi studio: Storie di successo dai nostri clienti
Caso di studio 1: Automotive EV Drivetrain Gears
Sfida: Necessario un produttore di veicoli elettrici leader 50,000 ingranaggi elicoidali (module 2 mm, ISO grade 6) for their new drivetrain. The gears required low noise, alta durata, and a 4-week lead time—manual machining couldn’t meet the timeline or precision.
Soluzione: We used CNC hobbing for rough machining and CNC grinding for finishing. We chose alloy steel (4140) trattato di calore a 55 HRC, with zinc plating for corrosion resistance. Nostro 24/7 production line ran 10 hobbing machines simultaneously.
Risultato: Consegnato 50,000 gears in 3.5 weeks with 99.95% Tasso privo di difetti. Il cliente ha riferito a 20% reduction in drivetrain noise and a 15% longer gear life compared to their previous supplier.
Caso di studio 2: Aerospace Landing Gear Bevel Gears
Sfida: An aerospace company needed 200 titanium alloy bevel gears (ISO grade 4) for aircraft landing gear. The gears required high strength (resistenza alla trazione >900 MPA) and tight runout tolerance (± 0,003 mm).
Soluzione: We used 5-axis CNC machining for rough shaping and CNC gear grinding for finishing. We heat-treated the titanium alloy (Ti-6al-4v) A 35 HRC and added a phosphating treatment for lubrication. We inspected each gear with a CNC gear tester.
Risultato: All gears passed FAA certification. The client noted that the gears handled 20% more load than their previous design, senza usura dopo 1,000 test landings.
Perché scegliere noi: Our Strengths as Your CNC Gear Partner
Quando scegli il nostro Lavorazione di ingranaggi CNC Servizi, you get more than a supplier—you get a partner focused on your success. Ecco il Reasons to Choose us:
- Competenza & Esperienza: Il nostro team ha 20+ anni in Gear Manufacturing, with engineers certified in ISO 1328 e standard aerospaziali (AS9100). Abbiamo lavorato con 500+ Clienti attraverso Automotive, aerospaziale, and industrial sectors.
- Attrezzatura avanzata: We operate 30+ Macchine a 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 precisione.
- Garanzia di qualità: Il nostro iso 9001:2015 and AS9100-certified facility includes in-house gear testers, CMMS, and material labs. Every gear undergoes 3 ispezioni (pre-machining, mid-process, finale) per garantire la conformità.
- Flexible Lead Times: We offer rush services for prototypes (velocemente come 3 giorni) and scalable production for high-volume orders. Nostro 24/7 production line cuts lead times by 30% contro. concorrenti.
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.