Gears
Premium Gears for Industrial and Mechanical Applications
Gears are the fundamental components that power modern machinery across industries. Our precision-engineered gears deliver unmatched performance, durability and efficiency for your mechanical systems.
Key Product Specifications
- Material: High-grade alloy steel (SAE 8620, 4140, 4340)
- Hardness: 58-62 HRC (case hardened)
- Precision Class: AGMA 9-13 (DIN 3-5 equivalent)
- Gear Types: Spur, helical, bevel, worm, planetary
- Module Range: 0.5 to 20
- Diameter Range: 10mm to 2000mm
- Surface Finish: Ra 0.4 to 1.6 μm
- Load Capacity: Up to 5000 Nm torque transmission
- Operating Temperature: -40°C to +150°C
Gears Performance Comparison
| Parameter | Standard Gears | Our Premium Gears |
|---|---|---|
| Efficiency | 92-95% | 97-99% |
| Service Life | 15,000-20,000 hours | 30,000-50,000 hours |
| Noise Level | 70-80 dB | 55-65 dB |
| Maintenance Interval | 500 operating hours | 1000 operating hours |
| Warranty Period | 1 year | 3 years |
Gears FAQ Section
Q: What lubrication is recommended for these gears?
A: We recommend using ISO VG 220 synthetic gear oil for most applications. For high-temperature environments (above 100°C), use polyurea-based grease with EP additives. Always follow the lubrication intervals specified in the maintenance manual - typically every 1000 operating hours under normal conditions.
Q: How do I determine the correct gear module for my application?
A: The gear module (pitch) should be selected based on torque requirements and space constraints. As a general rule: Module = (Pitch Diameter) / (Number of Teeth). For high-torque applications, choose larger modules (2-5), while precision applications benefit from smaller modules (0.5-1.5). Our engineering team can help calculate the optimal module based on your specific load and speed requirements.
Q: What's the lead time for custom gear manufacturing?
A: Standard lead times range from 2-6 weeks depending on gear complexity: 2-3 weeks for standard spur/helical gears, 3-4 weeks for bevel gears, and 4-6 weeks for custom planetary gear sets. Expedited services are available at 30-50% faster turnaround for urgent requirements.
Material Specifications
| Material Grade | Tensile Strength | Yield Strength | Impact Toughness | Recommended Applications |
|---|---|---|---|---|
| SAE 8620 | 850 MPa | 650 MPa | 55 J | Automotive, moderate load gears |
| SAE 4140 | 950 MPa | 750 MPa | 45 J | Industrial machinery, heavy-duty gears |
| SAE 4340 | 1100 MPa | 900 MPa | 40 J | Aerospace, extreme load applications |
Additional Gears FAQ
Q: What surface treatments are available for corrosion protection?
A: We offer multiple surface treatment options: standard black oxide coating (5-10μm), zinc-nickel plating (15-25μm), and DLC (Diamond-Like Carbon) coating (2-5μm) for maximum wear resistance. For marine applications, we recommend our proprietary MarineShield™ treatment which provides 2000+ hours salt spray resistance.
Q: How are your gears inspected for quality control?
A: Every gear undergoes 4-stage quality inspection: 1) Raw material spectrometry verification, 2) Dimensional checks with CMM (Coordinate Measuring Machine), 3) Hardness testing at 3 points minimum, 4) Final operational testing on our gear test rigs simulating actual load conditions. We maintain full traceability with individual gear ID numbers.
Q: What's your maximum production capacity for large gears?
A: Our facility can manufacture gears up to 2 meters in diameter with weight capacity up to 5 tons per gear. For larger requirements, we have strategic partnerships with specialized foundries capable of producing gears up to 8 meters diameter. Monthly production capacity reaches 15,000 standard gears or 500 custom large gears.
Installation Guidelines
- Always clean mating surfaces with solvent before installation
- Use proper alignment tools (dial indicators/laser alignment)
- Apply initial lubrication before first operation
- Follow specified bolt torque sequences
- Conduct trial run at 25% load for first 2 hours
- Check backlash and contact pattern after 50 operating hours
Final Gears FAQ
Q: What's your policy for gear repairs or reconditioning?
A: We offer comprehensive gear repair services including: tooth profile restoration, bearing seat refurbishment, hardness restoration, and dynamic balancing. Most repairs carry 1-year warranty. Evaluation reports with repair recommendations are provided within 3 business days of receiving the gear.
Q: Do you provide CAD models for your standard gear products?
A> Yes, all standard gears have downloadable 3D CAD models (STEP, IGES, Parasolid formats) available on our product pages. For custom gears, we provide 3D models for approval before manufacturing begins at no additional cost.
Q: What industries commonly use your gear products?
A: Our gears serve diverse industries: automotive (30%), heavy machinery (25%), renewable energy (20%), aerospace (15%), and marine (10%). We maintain specialized product lines for each sector with industry-specific certifications including API, AGMA, DNV, and AS9100.
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