Custom Gear Manufacturing

Custom-made Product Examples

Alloy Steel

Module: 1.0

• Material: SCM415(AISI 4115)
• Module: 1.0
• DP: 25.4
• Number of teeth: 10
• Helix angle: 35°

• Material: SCM415(AISI 4115)
• Module: 1.0
• DP: 25.4
• Number of teeth: 14
• Helix angle: 35°

• Material: SCM415(AISI 4115)
• Module: 1.0
• DP: 25.4
• Number of teeth: 21
• Helix angle: 35°

• Material: SCM415(AISI 4115)
• Module: 1.0
• DP: 25.4
• Number of teeth: 14
• Helix angle: 0°

Module: 1.25

• Material: SCM415(AISI 4115)
• Module: 1.25
• DP: 20.3
• Number of teeth: 48
• Helix angle: 35°

• Material: SCM415(AISI 4115)
• Module: 1.25
• DP: 20.3
• Number of teeth: 20
• Helix angle: 35°

• Material: SCM415(AISI 4115)
• Module: 1.25
• DP: 20.3
• Number of teeth: 20
• Helix angle: 35°

• Material: SCM415(AISI 4115)
• Module: 1.25
• DP: 20.3
• Number of teeth: 38
• Helix angle: 35°

• Material: SCM415(AISI 4115)
• Module: 1.25
• DP: 20.3
• Number of teeth: 15
• Helix angle: 35°

Module: 1.3

• Material: SCM415(AISI 4115)
• Module: 1.3
• DP: 19.5
• Number of teeth: 21
• Helix angle: 35°

• Material: SCM415(AISI 4115)
• Module: 1.3
• DP: 19.5
• Number of teeth: 16
• Helix angle: 35°

Module: 1.5

• Material: SCM415(AISI 4115)
• Module: 1.5
• DP: 16.9
• Number of teeth: 21
• Helix angle: 35°

DP: 18

• Material: SCM415(AISI 4115)
• DP: 18
• Number of teeth: 12
• Helix angle: 35°

Basics of Spiral Bevel Gears

What is Spiral Bevel Gears?

Spiral bevel gears feature a curved tooth pattern on a pitch cone along with a torsion angle. They offer smoother motion transmission compared to straight bevel gears or Zerol bevel gears (as explained below), resulting in significant noise and vibration reduction at high speeds (10 m/s or more).

What makes Spiral Bevel Gears Unique?

In the case of spur gears, for instance, when cutting gears with a module of 1, you can utilize a hob (cutting tool) with a module of 1, regardless of the tooth ratio. However, when it comes to spiral bevel gears, the theoretical cutter diameter is determined by considering various factors, including the tooth ratio, tooth width, torsion angle, and gear module. The theoretical cutter diameter can vary significantly based on these specifications mentioned earlier.
In essence, even if you have numerous cutters, they may not suffice because the same module can yield different theoretical cutter diameters depending on the tooth ratio. This implies that a standardized approach is needed.

Currently, when cutting small modules like ours (2.5 modules or smaller), cutter diameters are standardized to some extent, such as 0.5 inch, 1.1 inch, 1.5 inch, 2 inch, and 3.5 inches. A standard cutter is selected to approximate the theoretical cutter diameter calculated based on the various specifications. For example, if the theoretical cutter diameter is 1.2 inches, you can choose either a 1.1 inch or 1.5 inch standard cutter.
Considering that standard cutters are further adjusted based on factors such as cutter No. (blade tilt angle) and point width (cutting edge width) in accordance with gear specifications, it becomes evident that a substantial quantity of cutters is still required.
Therefore, despite the theoretical complexity of spiral bevel gears, they represent an appealing choice for manufacturers due to their high degree of adaptability.

Uses of Spiral Bevel Gears

1. Automotive Industry

In the realm of automobiles, spiral bevel gears are pivotal in the differential system, ensuring drive wheels can rotate at different speeds during turns. Their smooth meshing attributes make them ideal for quieter operations. Additionally, they're incorporated in specific transmission setups and are fundamental in 4WD vehicles, facilitating balanced power distribution to both front and rear axles.

2. Industrial Equipment

Industrial machinery, especially those requiring power to be transferred at right angles, heavily relies on spiral bevel gears. They're a common sight in power tools like drills, where direction change is essential, and in conveyor systems, ensuring materials move smoothly across different levels.

3. Marine Industry

Marine vessels utilize spiral bevel gears in their propulsion mechanisms, transferring power efficiently from engines to propellers. Their precision also finds use in advanced navigation systems, allowing for accurate steering and movement in the vast marine environment.

Manufacturing Process

STEP 1: Material Preparation

The appropriate material is selected based on desired gear properties, ensuring optimal strength and durability.

STEP 2: Cutting

The chosen material is cut into manageable sizes, preparing it for subsequent processing.

STEP 3: Heat Treatment

The cut pieces undergo heat treatment to enhance their mechanical properties, such as hardness and toughness.

STEP 4: Lathe Machining

The heat-treated pieces are shaped on a lathe, ensuring symmetry and preparing them for detailed machining.

STEP 5: Gear Cutting

The teeth of the gear are formed using specialized gear cutting machines, creating the unique helical shape.

STEP 6: Broaching

Internal features, like keyways or splines, are created using a broaching process, which removes material with a toothed tool.

STEP 7: Carburizing with high frequency

The gear undergoes a carburizing process, enriched with carbon, and is then treated with high-frequency heat to harden its surface.

STEP 8: Shaft Grinding

The gear's shaft is finely ground to achieve precise dimensions, ensuring a perfect fit in its assembly.

STEP 9: Gear grinding

The gear teeth are finely ground using specialized equipment, ensuring smooth engagement and precise tooth profiles, enhancing the gear's operational performance.

STEP 10: Inspection

The final gear is rigorously inspected for quality and compliance with design specifications. Advanced tools and machines are used to measure dimensions, alignments, and other critical parameters to guarantee optimal performance in real-world applications.