Custom Helical Gear Manufacturer
Helical Gear
China Simis Company is a specialized OEM custom manufacturer of high-precision Helical Gears. Helical gears are vital components in power transmission systems, known for their smoother, quieter operation and higher load capacity compared to spur gears, due to the gradual engagement of their angled teeth.
Helical gears are subjected to extreme cyclical loading, high contact stress, and torsional forces. We utilize Precision Forging for critical, high-torque applications (automotive, mining) to ensure maximum fatigue strength and grain flow alignment. We guarantee superior performance through controlled manufacturing of the initial Gear Blank, precise Gear Cutting (Hobbing), and mandatory Finishing (Grinding) and specialized Heat Treatment to meet AGMA or ISO quality standards.
What are the manufacturing processes for helical gears?
The performance of a helical gear is determined by both the integrity of the blank (forging/casting) and the precision of the finishing operations. We mainly adopt 6 core processes including Precision Forging, Open Die/Ring Forging, Casting, Gear Cutting, Gear Grinding and Heat Treatment to meet different helical gear production needs.
| Manufacturing Process | Component Focus | Material Focus | Key Advantage for Gear Performance |
| Precision Forging (Blank Forming) | Small to Medium-sized Gears (Automotive Transmissions). | Alloy Steel (20CrMnTi, 42CrMo). | Optimizes Grain Flow. Provides uniform material structure, maximizing resistance to bending and contact fatigue in high-stress gear sets. |
| Open Die Forging / Ring Forging | Large Gear Blanks (Wind Turbines, Heavy Industrial Reducers). | Alloy Steel, High-Carbon Steel. | Ensures Internal Soundness and Core Strength. Refines the material structure in massive blanks, ensuring high fatigue life for deep tooth sections. |
| Casting (Blank Forming) | Large, Slow-Speed Gears. | Cast Iron, Cast Steel, Copper/Aluminum Alloys. | Cost-effective for large-diameter industrial gears or where the vibration-damping properties of Cast Iron are desired. |
| Gear Cutting (Hobbing/Milling) | All Gears. | All Gear Materials. | Primary tooth generation process. Requires high-precision CNC equipment to achieve the correct helical angle, lead, and tooth profile. |
| Gear Grinding (Finishing) | High-Accuracy Gears (AGMA 10+). | Hardened Steel/Alloy Steel. | Mandatory Post-Heat Treatment step to correct minor distortion from hardening and achieve the highest possible precision (low noise, high AGMA grade). |
| Heat Treatment (Hardening) | All Steel Gears. | Alloy Steel (Carburizing), Carbon Steel (Induction Hardening). | Critical. Achieves high surface hardness (HRC 58-62) for wear resistance while maintaining a tough, ductile core for impact resistance. |
How to Select Helical Gear Materials?
Material selection focuses on achieving high hardenability (depth of hardness after heat treatment) and core toughness, or low friction/weight. We provide 6 main material types including Alloy Steel, Carbon Steel, Copper Alloy, Aluminum Alloy, Cast Iron and Stainless Steel for helical gear production, each with specific performance advantages matching different application requirements.
| Material Type | Primary Performance Requirement | Typical Gear Application & Service |
| Alloy Steel (AISI 8620, 4340) | Highest Strength, Deep Hardenability, Excellent Core Toughness. | Automotive Gearboxes, Aerospace, Mining Machinery; ideal for case hardening. |
| Carbon Steel (AISI 1045, 1050) | Moderate Strength, Good for Induction Hardening. | General industrial equipment, agricultural machinery; cost-effective for medium loads. |
| Copper Alloy (Bronze/Brass) | Low Friction, Excellent Wear Resistance (Mating with Hardened Steel), Corrosion Resistance. | Low-speed worm wheel applications, marine equipment, fluid mixers. |
| Aluminum Alloy | Lightweight, Low Inertia, High Thermal Conductivity. | High-speed, moderate-torque applications (e.g., aerospace actuators, high-speed packaging machinery). |
| Cast Iron (Ductile/Gray) | Good Damping, Cost-Effective for Large Housing-Integrated Gears. | Slow-Speed Industrial Drives, Agricultural Machinery. |
| Stainless Steel (304, 316) | Corrosion Resistance and High Strength. | Gears exposed to moisture, chemical, or marine environments. |
What Measures Ensure Helical Gear Quality Assurance and Precision Geometry?
Gear manufacturing requires metrology far exceeding standard machining to guarantee smooth power transfer and quiet operation. Our core quality assurance measures include profile & lead testing, accuracy grading, metallurgical verification and dynamic balancing to guarantee each helical gear meets strict AGMA/ISO precision standards.
·Profile and Lead Testing:
Specialized CNC gear inspection machines are used to measure the Tooth Profile and Lead (Helix Angle) deviation, ensuring accurate load distribution across the face width.
·Accuracy Grading:
Gears are certified to industry standards, typically AGMA Quality Class 8 to 12 or equivalent ISO Grades, verifying pitch, runout, and composite error. Grades 10+ usually require grinding.
·Metallurgical Verification:
Post-heat treatment, testing includes Case Depth Measurement (for carburized gears) and Microhardness Testing to confirm the surface hardness and microstructure meet wear resistance specifications.
·Dynamic Balancing:
For high-speed applications (e.g., aerospace), residual imbalance is measured and corrected to prevent vibration and ensure smooth operation.
What Are the Key Application Areas for Helical Gear?
Our custom-forged and cast helical gears are essential in demanding applications where efficiency, smooth operation, and high torque density are required, covering automotive, wind turbines, industrial reducers, mining & metallurgy, and power plants sectors.
| Application Sector | Typical Helical Gear Use | Primary Operating Challenge | Material/Process Highlight |
| Automotive | Manual/Automatic Transmissions, Differentials. | High Torque Density, Low NVH, High RPM Service. | Forged Carburizing Steel (20CrMnTi); Precision Ground Teeth (ISO 5-7). |
| Wind Turbines | High-Speed Stage Gearboxes. | Extreme Cyclical Fatigue, Massive Torque Load, Reliability. | Open Die/Ring Forged Alloy Steel; UT Inspected Blanks; ISO Class 6 Grinding. |
| Industrial Reducers | Heavy Load Speed Reducers, Conveyor Drives. | Continuous Operation, High Torque Transfer, Low Noise. | Forged 42CrMo (Quenched & Tempered) or Large Cast Steel Gears. |
| Mining & Metallurgy | Mill Drives, Hoisting Equipment. | Severe Operating Environment, Shock Load Resistance. | Forged Alloy Steel (Full Traceability); Hardness verified to resist deep pitting. |
| Power Plants | Turbine Gearboxes, Feed Pump Drives. | High Reliability in Critical Service, High RPM/Load. | Forged 4140/4340 (Induction Hardened); Detailed NDT required. |
What Are the Advantages of Simis OEM Custom Helical Gear Manufacturing?
Partnering with Simis ensures certified precision, superior fatigue life, and reliable performance in demanding gear applications:
·Forging for Fatigue Life:
We prioritize Precision Forging of steel gear blanks, providing the optimal grain structure and material density essential for maximizing the load capacity and cyclical fatigue resistance of the gear.
·Precision Gear Grinding:
Our advanced finishing capability allows us to produce gears to AGMA Class 10 and higher, minimizing operational noise and correcting heat treatment distortion for superior component life.
·Certified Case Hardening:
We utilize controlled atmosphere furnaces for Carburizing and other thermal treatments, guaranteeing precise Case Depth and surface hardness for maximum resistance to pitting and wear.
·Full Dimensional Certification:
We provide comprehensive inspection reports (including profile, lead, and runout charts) from specialized gear inspection equipment, certifying compliance with all geometric and quality standards.
How to Get a Quote for Custom Helical Gears?
China Simis Company is your expert global partner for custom forged and cast helical gears, engineered for maximum torque capacity, low noise, and superior precision.
Please submit your 2D technical drawings, CAD models, and specific requirements for Module/Diametral Pitch, Number of Teeth, Helix Angle, Face Width, AGMA Quality Class, material grade (AISI), and required Case Depth to our engineering department for a consultation and detailed quotation.
