Industrial Grade Components Spiral Bevel Gear for Industry

1. 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 and Stainless Steel.

A. Selection of Equipment:

B. Setting of cutting parameters
Reasonably set cutting speed, feed rate, cooling conditions and other parameters to avoid problems such as material deformation or cracking caused by overheating.

C. Safety operating procedures: 

D. Quality inspection:
After cutting,needs to check the dimensional tolerances, surface quality, and the presence of defects.

E. Environmental protection measures 

2. 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.

3. 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.

4. 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.

5. Burr Removing

Improve Safety: 
Removing burrs can significantly reduce this risk of injury to operators.

Enhance Mechanical Performance: 
Removing burrs can help extend the lifespan of parts and reduce the likelihood of malfunctions.

Improving Assembly Quality: 
Removing burrs can ensure smooth fit between parts.

Improving Surface Smoothness: 
Removing burrs is an important step in improving the surface quality of gears

Reduce Noise and Vibration: 
By removing the burrs, the working condition of gears can be improved, making their operation quieter and more stable.

Optimizing Contact Surface: 
Removing burrs helps maintain correct tooth contact

6. Tooth Grinding:
After deburring, gears undergo further precision processing. These accuracy grades are critical in determining the gear's performance and suitability for various applications.

Improving Gear Accuracy: 
Enhancing the geometric accuracy of gears by grinding teeth, errors

Improving Surface Quality:
Grinding teeth can remove small defects and burrs on the surface of gears, 

Enhance Contact Quality

Reduce Noise:
High quality grinding treatment helps to reduce the noise generated by gears during operation,

Improving Transmission Efficiency:
After fine grinding, gears can achieve higher transmission efficiency due to better fitting accuracy and lower friction coefficient.

7. Gear Cleaning:

Gear Cleaning to remove chips, oil stains, or other impurities generated during the machining process. This cleaning process is crucial for ensuring the quality of subsequent processing and the performance of the final product.

Remove chips and debris: After each processing stage, clean the metal chips and other debris on the gear to avoid these substances affecting the subsequent processing accuracy.

Cleaning the surface: Ensure that the gear surface is free of grease, dust, or other contaminants

Improving assembly quality: Clean components help improve accuracy during assembly and reduce wear or malfunctions caused by foreign objects.

8. Inspection:

As a key component in mechanical transmission systems, the accuracy and quality of bevel gears directly affect the performance of the entire system. Therefore, comprehensive and accurate testing is crucial in the production process of bevel gears.

Testing process and methods

Single piece inspection

Measurement of common normal line length

Tooth height measurement

Chord tooth thickness measurement

Pairing detection

Axle angle detection

Contact spot detection

Tooth surface backlash detection

Tooth tip clearance detection

Rolling test
Accuracy testing
Tool assisted testing

Main testing elements
Geometric dimensions: including basic dimensional parameters such as tooth profile, tooth height, common normal length, chord tooth thickness, etc.
Surface quality: such as surface roughness, hardness distribution, etc.
Mesh characteristics: factors that reflect the mating state between gears, such as contact spots, tooth flank clearance, and tooth tip clearance.
Dynamic performance: performance indicators such as rolling noise, vibration level, etc. during operation.

9. Package, Warehousing & Shipping:

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.

Samples delivery usually by Couriers, Small Orders by Air, Most shipments 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.