High Efficiency Engineering Worm Gears for Automation Equipment

Material Preparation:
Select suitable materials according to design requirements, typically steel or other alloys, to ensure the gear has adequate strength and wear resistance. Commonly materials include: 20CrMnTi, 45#, 40Cr, 20CrMo, 42CrMo, CuSn12, CuAl10Fe3.

Cutting, Forging, or Casting:
The preparation of materials for ordinary-sized gears is done by cutting cylindrical raw materials with an electric saw. For large-sized (diameters of 2m, 1.8m, 0.8m, etc.) or high-strength requirement gears, forging is commonly used for initial shaping; for more complex-shaped gears, casting processes of Metallurgy Powder may be employed.

Termal Refined:

Quenching: Gears are first heated to a certain temperature and held for a period to ensure uniform temperature throughout the workpiece. They are then rapidly cooled, usually using oil, water, or air as cooling mediums, significantly increasing hardness and strength.

High-Temperature Tempering:

Post-quenching, gears become very brittle and are not suitable for direct use. Thus, they undergo high-temperature tempering, being reheated to temperatures typically between 500-650°C, held for a period, and then slowly cooled. This step reduces internal stresses, improves brittleness, and adjusts the material's hardness and toughness, achieving optimal comprehensive mechanical properties.

Rough Machining (Initial Processing):

In the initial machining phase, the gear blank undergoes a series of mechanical processing methods, including turning and milling, which meticulously shape the raw material closer to its final design specifications. During this crucial step, not only is any excess material carefully removed to minimize waste and reduce the workpiece to near its intended size, but the fundamental outline and basic features of the gear are also precisely established.

Heat Treatment:

To enhance the gear's hardness and wear resistance, heat treatments such as carburizing quenching, high-frequency quenching, etc., are usually performed. The heat treatment process can significantly improve the gear's mechanical properties.

 Carburizing involves heating the gear to a high temperature in the presence of a carbon-rich environment, allowing carbon atoms to diffuse into the surface layer of the metal, thereby increasing its carbon content. This process is followed by rapid cooling, or quenching, typically in oil or another suitable medium, which hardens the surface while keeping the core relatively softer and more ductile. This combination enhances the gear's durability and extends its operational life under high-load conditions.

High-frequency Qunching, utilizes induction heating to target specific areas of the gear with high-frequency electrical currents. This method heats the surface layer quickly and uniformly, achieving deep and consistent hardening without affecting the material's core properties. It is particularly effective for enhancing wear resistance and fatigue strength in localized regions of the gear that experience the most stress during operation.

Precision Machining:
After heat treatment, gears undergo further precision processing. These accuracy grades are critical in determining the gear's performance and suitability for various applications.

The final stages of precision processing, therefore, play a pivotal role in achieving the desired accuracy grade, ensuring that each gear performs optimally within its intended application. By meticulously controlling factors like tooth profile, pitch, runout, and surface roughness, manufacturers can produce gears that not only meet but exceed the necessary standards for performance and reliability.

Inspection:

Testing and Quality Control encompass comprehensive evaluation and assurance processes for both semi-finished and finished gear products. This includes not only routine visual inspections and dimensional accuracy checks but also critical assessments post-heat treatment, such as surface hardness testing, core hardness testing, and microstructure analysis. These evaluations are essential to verify the material properties and structural integrity of the gears, ensuring they meet stringent performance criteria.

By implementing meticulous testing and quality control procedures, manufacturers can guarantee the reliability, performance, and longevity of their gear products, thereby meeting exacting industry standards and customer expectations. Comprehensive documentation and analysis of these tests further enable continuous improvement in manufacturing processes and product quality.

Gear packaging usually uses customized foam or plastic mold to fix the product and prevent it from moving during transportation. The gears will be wrapped in rust proof paper or a film coated with rust proof oil to prevent corrosion. Afterwards, place it in a sturdy cardboard or wooden box and fill it with cushioning material to reduce the impact of vibration and collision. For particularly large or heavy gears, metal frames or trays may be used to reinforce the packaging.

The importance of safe packaging lies in its ability to ensure that gears remain intact during transportation and storage. Good packaging can effectively prevent gears from being physically damaged, corroded, and affected by environmental factors such as moisture and dust, thereby ensuring that the quality and performance of gears are not compromised. In addition, appropriate packaging can simplify the logistics process, improve handling efficiency, and reduce overall costs. Therefore, safe packaging is a key step in ensuring the satisfaction of end users with the product.

Sample delivery usually by Courier, Small Order by Air, Most shipment by Sea.

Since its establishment, EnDao Industry and its cooperative factories have accumulated over 20 years of professional experience. We specialize in producing products such as spur, helical, bevel, large-sized forged gears, and gearboxes. With our excellent product quality and customer service, we have established a good reputation in the industry.

We have not only established long-term cooperative relationships with numerous high-quality raw material suppliers, but also hold shares in heat treatment plants. This means that every step from raw material procurement to final product can be optimized for cost control and quality assurance. This vertical integration greatly improves production efficiency, reduces costs, and ensures high-quality product output.
 

Above 20 years of Experience
Competitive Price & Stable Quality
Fast Delivery with Most Kinds of Gears
Welcome Both Small and Big Orders

Q: Are you a factory?
A: Yes, we are a factory that has invested in a heat treatment facility and have strong associations with numerous small and big partners to support our production processes.

Q: What is your MOQ (Minimum Order Quantity)?
A: Our standard MOQ is 20 pieces, but this is negotiable based on specific customer needs and requirements.

Q: Which port do you use for loading shipments?
A: Ningbo Port is our most convenient loading port, offering efficient shipping solutions for our customers.

Q: What products do you offer?
A: We specialize in manufacturing a wide range of metal gears and speed reducers. Our product line includes various types of metal gears such as helical, bevel, and large ring gears, the latter of which we produce through forging materials. Whether you need standard components or custom solutions, we have the capability to meet diverse industrial requirements.