Gear Machining
Brightening Your Ideas with Prototypes
We look forward to working hand-in-hand with you. As a gear prototype expert, our confidence comes from our hard work and strength.
We focus on providing complete gear prototypes, expanding our knowledge and experience in this field to provide professional prototype services to many well-known gear OEMs and suppliers worldwide.
Gear Machining - KeSuRapid
From proof of concept design reviews and custom parts system development engineering tests to industry projects, from rapid prototypes to custom prototypes, we support all levels of gear product development processes.
Machined Metal Parts
We specialize in a variety of gear prototyping developments and rapid manufacturing technologies, providing CNC machining, 3D printing, vacuum casting, rapid aluminum and alloy machining tooling, low volume CNC processes, and sheet metal processing.
The High Precision Machining - Gear rapid prototyping
01. Comprehensive CNC Machining
The best combination of 3-axis, 4-axis, and 5-axis CNC milling machines, equipped with machine tools with a stroke of more than 1 meter, gives us the expertise to machine custom gear parts flawlessly.
02. Prototype Achieves High Precision
KeSuRapid company provides a variety of optional cost-effective precision solutions. Rapid machining achieves integrated processes in two or more materials.
- CNC manufacturing team of professional engineers and machinists, optimized NC programming and efficient toolpaths.
- 5-axis continuous CNC machining for greater machining accuracy and flexibility.
- We pay attention to every design detail; gear tooth and hub details are machined to a minimum radius of R0.10mm.
- Excellent surface quality with a finished surface finish of Ra (μm) 0.2 and surface tolerance of ±0.025mm.
- Auxiliary EDM machining is necessary to meet the overall machining requirements of the gear part.
Types Of Gear
| Gear Type | Description | Applications | CNC Machining Considerations |
|---|---|---|---|
| Spur Gear | Teeth are parallel to the axis of rotation. | Simple mechanical systems, automotive transmissions | 3-axis machining, precision cutting of teeth |
| Helical Gear | Teeth are angled with respect to the axis. | Quiet operation, high load applications | 4-axis or 5-axis for angled cuts, tooth accuracy |
| Bevel Gear | Teeth form a conical shape, intersecting shafts. | Power transmission between non-parallel shafts | 5-axis machining, complex tooth geometry |
| Worm Gear | Non-coplanar shafts, one gear resembles a screw. | High reduction ratios, compact design | Specialized tooling, precise gear mesh |
| Planetary Gear | Central sun gear with orbiting planet gears. | High torque, compact systems, aerospace | Multiple axes, intricate assembly |
| Rack and Pinion | Linear motion converted to rotational motion. | Steering systems, automation | Straight machining, high precision for rack teeth |
| Internal Gear | Teeth are on the inside of a ring. | Compact, high gear ratio systems | Inverted tooth cutting, 5-axis for complex designs |
From Small Batch Customization to Pre-Production
We have the ability to provide rapid tooling of both alloy and soft steel and low volume production to deliver your end-use molded gear parts within 2-5 weeks. We provide cost-effective and rationalized advice from designs, materials, production processes, manufacturability, etc.
Precision Of Gear Machining
Applications of Gear Production
- Machinery Manufacturing: Essential for creating gears for various mechanical systems, defining motion and force transmission characteristics.
- Automotive Industry: Used in transmission systems, differential gears for vehicles.
- Aerospace Components: For gear parts used in aircraft engines, actuators, and other precision systems.
- Robotics: For high-precision gear sets in robotic arms, joints, and drive systems.
- Industrial Automation: In creating gears for conveyor systems, precision positioning.
Challenges in Gear Machining
- Complex Tooth Geometry: Gears often have complex tooth profiles, requiring advanced machining techniques and multi-axis capabilities.
- Material Selection: Gears are often made from high-strength materials, which can be challenging to machine and require specialized tooling.
- Gear Tooth Accuracy: Precise tooth profiles are critical for smooth and efficient gear operation, requiring tight tolerances.
- Surface Finish: Achieving a smooth surface finish on gear teeth is crucial for reducing noise and wear.
Innovations and Techniques
- 5-Axis CNC Machining: Enables the machining of complex gear tooth geometries with high precision and efficiency.
- High-Speed Machining (HSM): Utilizes high spindle speeds and feed rates to reduce machining time and improve gear tooth finish.
- Advanced Tooling: Specialized cutting tools and coatings are used to machine hard gear materials and achieve tight tolerances.
- Gear Hobbing and Shaping: Specialized techniques for producing accurate gear teeth.
Comparison of Gear Machining Techniques
| Technique | Best For | Advantages | Challenges |
|---|---|---|---|
| CNC Milling (3-5 Axis) | Complex geometries, high precision | High accuracy, versatility | Tool wear, material removal rate |
| EDM | Intricate details, hard materials | No mechanical stress, fine detail | Slow process, cost |
| Gear Hobbing | Precision gear tooth cutting | High speed, excellent tooth finish | Requires specific hobbing machines, setup complexity |
Frequently Asked Questions (FAQ)
- What is the typical lead time for a gear prototype?
- Lead times can vary based on the gear's complexity and material; typically, we can deliver prototypes within 2-5 weeks.
- What materials can you machine gears from?
- We machine gears from a variety of materials, including aluminum, steel, copper, titanium, stainless steel, nickel alloy, and various alloys, depending on the application.
- How do you ensure gear balance?
- We utilize precision balancing equipment and procedures to ensure that gears meet strict balance requirements, minimizing vibration and maximizing efficiency.
- What tolerances can you achieve on gear machining?
- We can achieve tight tolerances within ±0.01mm on gear manufacturing, depending on the specific features and requirements.
- Do you offer gear design services?
- Yes, we can collaborate with you on gear design optimization to ensure manufacturability and performance.