Our CNC Gear Machining Services
Elevate your machinery’s performance with our Usinagem de engrenagem CNC services—where advanced Tecnologia CNC meets decades of Gear Manufacturing especialização. We deliver high-precision gears (spurs, helicals, bevels, e mais) com tolerâncias apertadas, materiais duráveis, and superior surface finishes, tailored to automotive, Aeroespacial, e setores industriais. Partner with us for cost-effective, on-time gear solutions that keep your operations running smoothly.
What Is CNC Gear Machining?
Usinagem de engrenagem 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), Usinagem de engrenagem CNC uses pre-programmed Tecnologia CNC to automate cutting, modelagem, e acabamento, ensuring repeatable precision.
Na sua essência, o Gear Machining Process involves removing material from a workpiece (usually metal) to create teeth with specific profiles (Por exemplo, involute, cycloidal) e dimensões. 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.
Nossas capacidades: O que podemos entregar
Nosso 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 habilidades, and supported Gear Types:
| Categoria de capacidade | Detalhes | Specifications |
| Gear Types | Spurs, helicals, bevels, engrenagens de minhocas, engrenagens internas, planetary gears | Module range: 0.5–20 mm; Número de dentes: 5–200 teeth |
| Workpiece Size | Small precision gears to large industrial gears | Max diameter: 1,200 milímetros; Max weight: 500 kg |
| Volume de produção | Flexible for low-batch prototypes and mass production | Protótipos: 1–50 unidades; Produção em massa: 10,000–500,000+ units/year |
| Nível de precisão | Ultra-tight control for critical gear performance | Pitch error: ± 0,005 mm; Runout: ± 0,003 mm; ISO accuracy grade: 4–8 (para ISO 1328) |
| Personalização | Tailored to unique designs and industry standards | Supports custom tooth profiles, Materiais, 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
O 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:
- Projeto & Programação: We start with your 2D/3D CAD model (Por exemplo, ETAPA, 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.
- Preparação do material: The chosen material (Por exemplo, aço, latão) is cut into blanks (cylindrical or conical shapes) e tratado termicamente (se necessário) to improve hardness before machining.
- Usinagem áspera: 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.
- Acabar com a usinagem: We use precision tools (Por exemplo, gear shapers, trituradores) 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 Acabamento superficial (Por exemplo, moagem, lapping) Para reduzir o atrito e o desgaste. We also inspect the gear for dimensional accuracy using tools like gear testers.
Materiais: Suitable for CNC Gear Machining
Usinagem de engrenagem CNC relies on materials that balance strength, durabilidade, e maquiagem. Abaixo estão o Common Gear Materials nós trabalhamos com, along with their Propriedades do material e usos ideais:
| Material | Dureza (CDH) | Resistência à tracção (MPA) | Propriedades -chave | Aplicações típicas |
| Liga de aço (4140) | 28–32 (recozido); 50–55 (tratado termicamente) | 860–1.000 | Alta resistência, resistência ao desgaste, toughness | Automotive transmissions, industrial gearboxes |
| Aço inoxidável (304) | 18–22 | 515 | Resistência à corrosão, hygiene | Food processing machinery, marine gears |
| Latão (C36000) | 15–20 | 310 | Excelente máquina, baixo atrito | Small gears for electronics, instrumentation |
| Ferro fundido (GG25) | 180–220 HB (≈18–22 HRC) | 250 | Baixo custo, good damping capacity | Heavy-duty industrial gearboxes, pumps |
| Liga de titânio (Ti-6al-4V) | 30–35 | 900 | Alta proporção de força / peso, Resistência à corrosão | Aerospace gears, medical equipment |
Nosso Seleção de material process involves collaborating with you to match material properties to your gear’s operating conditions (Por exemplo, carregar, temperatura, ambiente)—ensuring long-lasting performance.
Tratamento de superfície: Enhancing Gear Performance
Gear Surface Treatment is critical for reducing wear, Melhorando a resistência à corrosão, and extending gear life. Below are our Acabamento superficial opções, along with their benefits and ideal uses:
| Treatment Methods | Rugosidade da superfície (Rá) | Principais benefícios | Ideal para |
| Gear Grinding | 0.4–1.6 μm | Ultra-smooth surface; reduces noise and friction | High-precision gears (ISO grade 4–5) for aerospace |
| Carburismo & Tireização | 1.6–3.2 μm | Aumenta a dureza da superfície (até 60 CDH); core remains tough | Engrenagens de transmissão automotiva (high load) |
| Batinho de zinco | 0.8–3.2 μm | Resistência à corrosão; baixo custo | Gears for outdoor equipment, electrical machinery |
| Lapping | 0.02–0.1 μm | Mirror-like finish; improves tooth contact accuracy | Precision instrument gears (Por exemplo, Relógios, sensores) |
| Fosfatando | 1.6–6.3 μm | Enhances lubrication; prevents rust | Gears in hydraulic systems, industrial pumps |
Nós adaptamos Post-Machining Treatment to your gear’s needs—whether you need corrosion protection for marine gears or noise reduction for automotive gears.
Tolerâncias: Precision for Reliable Gear Function
Gear Tolerances directly impact performance: even small errors can cause noise, vestir, or failure. We maintain strict Controle de tolerância Para atender aos padrões globais. Below are our Tolerâncias de precisão for key gear features:
| Gear Feature | Tolerance Levels | Padrão da Indústria (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 |
Nosso Tolerâncias de usinagem are calibrated to your gear’s ISO accuracy grade—from grade 8 (standard industrial gears) to grade 4 (high-precision aerospace gears).
Vantagens: Why Choose CNC Gear Machining?
Usinagem de engrenagem CNC offers clear benefits over manual or traditional methods. Abaixo estão a chave Advantages of CNC Gear Machining:
- Precisão superior: Com Vantagens de precisão like ISO grade 4 precisão, CNC ensures consistent tooth spacing and profile—critical for gears that mesh smoothly. Manual machining often struggles to reach grade 8 or better.
- Vantagens de custo: Para produção de alto volume, CNC automates labor-intensive steps (Por exemplo, hobbing, modelagem), reducing labor costs by 30–40% compared to manual methods. It also minimizes material waste (menor que 5%, vs.. 15–20% for manual).
- Flexibility for Custom Gears: CNC easily handles custom designs (Por exemplo, non-standard tooth profiles, engrenagens internas) 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 (Por exemplo, Desgaste da ferramenta, material defects) early, garantindo 99.9% defect-free production. Manual machining relies on operator judgment, leading to higher error rates.
Faster Lead Times: Máquinas CNC funcionam 24/7, Cortando os prazos de entrega por 50% Para ordens de alto volume. Um lote de 1,000 gears takes 1–2 weeks with CNC, vs.. 3–4 weeks with manual methods.
Indústria de aplicativos: Where CNC Gears Add Value
Nosso CNC Gear Services support diverse Setores da indústria, addressing unique challenges in each field. Abaixo estão chave Aplicações do setor and how we deliver value:
| Indústria | Application Fields | CNC Gear Uses | Os principais requisitos atendidos |
| Automotivo | Transmissions, differential systems, Veículo elétrico (Ev) drivetrains | Engrenagens de esporão, engrenagens helicoidais, planetary gears | Alto volume (100,000+ unidades/ano); ISO grade 6–7; noise reduction |
| Aeroespacial | Motores de aeronaves, landing gear systems, satellite mechanisms | Titanium alloy gears, bevel gears | Materiais leves; ISO grade 4–5; high temperature resistance |
| Máquinas industriais | Sistemas transportadores, bombas, compressores, wind turbines | Large helical gears, worm gears | Alta capacidade de carga; ISO grade 7–8; Resistência à corrosão |
| Eletrônica | Small motors (Por exemplo, drones, robots), 3D printers | Micro gears (module 0.5–1 mm), brass gears | Miniature size; baixo atrito; ISO grade 6–7 |
| Médico | Surgical robots, Equipamento de diagnóstico | Stainless steel gears, titanium gears | Biocompatibilidade; Resistência à corrosão; ISO grade 5–6 |
Técnicas de fabricação: Métodos avançados que usamos
To deliver top-tier gears, Usamos o estado da arte Gear Manufacturing Techniques e Machining Techniques. Below are our core methods:
- Fresagem 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 (Por exemplo, engrenagens automotivas).
- CNC Gear Shaping: Uses a reciprocating cutter (shaper) to create internal or external gears. Better than hobbing for complex shapes (Por exemplo, engrenagens internas, 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-Usinagem do eixo CNC: For complex gears (Por exemplo, engrenagens chanfradas, spiral gears). The 5-axis system adjusts the workpiece’s angle in real time, ensuring accurate tooth profiles on all sides.
Fio EDM (Usinagem de descarga elétrica): Used for micro gears (module <1 milímetros) or hard-to-machine materials (Por exemplo, titânio). Uses electrical sparks to cut teeth without physical contact—ideal for intricate designs.
Estudos de caso: Histórias de sucesso de nossos clientes
Estudo de caso 1: Automotive EV Drivetrain Gears
Desafio: Um fabricante de EV líder necessário 50,000 engrenagens helicoidais (module 2 milímetros, ISO grade 6) for their new drivetrain. The gears required low noise, alta durabilidade, and a 4-week lead time—manual machining couldn’t meet the timeline or precision.
Solução: We used CNC hobbing for rough machining and CNC grinding for finishing. We chose alloy steel (4140) tratado termicamente para 55 CDH, with zinc plating for corrosion resistance. Nosso 24/7 production line ran 10 hobbing machines simultaneously.
Resultado: Entregue 50,000 gears in 3.5 weeks with 99.95% taxa livre de defeitos. O cliente relatou um 20% reduction in drivetrain noise and a 15% longer gear life compared to their previous supplier.
Estudo de caso 2: Aerospace Landing Gear Bevel Gears
Desafio: An aerospace company needed 200 titanium alloy bevel gears (ISO grade 4) for aircraft landing gear. The gears required high strength (resistência à tracção >900 MPA) and tight runout tolerance (± 0,003 mm).
Solução: We used 5-axis CNC machining for rough shaping and CNC gear grinding for finishing. We heat-treated the titanium alloy (Ti-6al-4V) para 35 HRC and added a phosphating treatment for lubrication. We inspected each gear with a CNC gear tester.
Resultado: All gears passed FAA certification. The client noted that the gears handled 20% more load than their previous design, with no wear after 1,000 test landings.
Por que nos escolher: Our Strengths as Your CNC Gear Partner
Quando você escolhe nosso Usinagem de engrenagem CNC serviços, you get more than a supplier—you get a partner focused on your success. Aqui está o Reasons to Choose us:
- Especialização & Experiência: Nossa equipe tem 20+ anos depois Gear Manufacturing, with engineers certified in ISO 1328 e padrões aeroespaciais (AS9100). Nós trabalhamos com 500+ clientes em todo o automóvel, Aeroespacial, and industrial sectors.
- Equipamento avançado: We operate 30+ Máquinas 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 Precisão.
- Garantia de qualidade: Nosso ISO 9001:2015 and AS9100-certified facility includes in-house gear testers, Cmms, and material labs. Every gear undergoes 3 Inspeções (Pré-fazenda, mid-process, final) para garantir a conformidade.
- Flexible Lead Times: We offer rush services for prototypes (Tão rápido quanto 3 dias) and scalable production for high-volume orders. Nosso 24/7 production line cuts lead times by 30% vs.. concorrentes.
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.