Precision Forged Gears - Core Power Components of High-End Transmission Systems

I. Product Positioning

Precision forged gears are high-end transmission components manufactured through precision forging processes. They are made from high-quality alloy structural steel and carburized steel as base materials, undergoing multiple core processes including die forging forming, precision machining, and carburizing and quenching. Widely used in various power transmission systems, they perform key functions of torque transmission and speed regulation, serving as core parts ensuring efficient, stable, and low-noise operation of equipment. They meet the high-precision transmission needs of multiple fields such as automobiles, construction machinery, aerospace, and industrial machinery.

II. Core Advantages

1. Combined high strength and toughness: Adopting die forging forming process, the gear metal flow is continuous and intact without cutting. Combined with carburizing and quenching (surface hardness HRC 58-62) or induction hardening process, the tooth tensile strength is ≥1500MPa and impact toughness is ≥30J/cm². The load-bearing capacity is increased by more than 40% compared with ordinary machined gears, enabling resistance to high-frequency impact loads and extending service life.
2. Ultra-high machining precision: After forging, precision machining such as CNC hobbing and grinding is performed. The gear precision can reach GB/T 10095.1-2008 Grade 6 or above (some high-end products can reach Grade 4-5), with cumulative pitch error ≤±0.02mm and tooth direction error ≤±0.01mm. The meshing clearance is precisely controllable, effectively reducing transmission noise (operating noise ≤75dB) and improving transmission efficiency (transmission efficiency ≥98%).
3. Excellent wear resistance and fatigue resistance: The tooth surface is treated with phosphating, shot peening or nitriding, with surface roughness Ra ≤0.4μm and excellent wear resistance. Meanwhile, through optimizing tooth profile curve design (such as crowned teeth, relieved teeth), meshing impact is reduced. The tooth root bending fatigue strength is ≥800MPa and contact fatigue strength is ≥1200MPa, extending the fatigue life by 2-3 times compared with conventional gears.
4. High material utilization rate and cost optimization: The precision forging process can realize near-net shaping of gears, with machining allowance only 0.5-1.5mm and material utilization rate over 85% (ordinary machined gears have a material utilization rate of only 50-60%). This significantly reduces subsequent machining workload, lowering production costs and cycles.
5. Strong adaptability and customization capability: According to customers' transmission system requirements, it can customize module (m 1-12), number of teeth (z 10-120), tooth width (15-200mm) and gear type (straight teeth, helical teeth, bevel teeth, herringbone teeth, etc.). It is compatible with complex working conditions such as high temperature (≤400℃), high speed (linear speed ≤50m/s) and high load, supporting personalized customization of multiple specifications and scenarios.

III. Key Technical Parameters

IV. Application Fields

• Automobile industry: Engines, gearboxes, drive axles, steering systems (passenger cars, commercial vehicles, new energy vehicles);
• Construction machinery: Transmission systems and traveling mechanisms of excavators, loaders, cranes, rollers;
• Industrial machinery: General mechanical transmission components such as machine tool headstocks, reducers, conveyors, printing machines;
• Aerospace: Small aero-engines, UAV transmission systems (high-end precision models);
• New energy field: Wind power gearboxes, photovoltaic equipment transmission mechanisms, energy storage equipment reduction components.

V. Quality Assurance

1. High-quality steel from well-known domestic and foreign steel mills is selected as raw materials, with material certificates and mechanical performance test reports provided to ensure base material quality;
2. The entire production process complies with ISO 9001:2015 quality system and IATF 16949 automotive industry quality standards. Key processes (forging, heat treatment, precision machining) are equipped with online testing equipment to achieve 100% full inspection;
3. Finished products undergo multiple inspections such as 3D coordinate measurement, tooth profile and direction tester detection, metallographic analysis, non-destructive testing (magnetic particle testing, ultrasonic testing) to ensure no cracks, inclusions and other defects;
4. One-stop services from product design, mold development, sample trial production to mass production are provided. Free technical support, fault diagnosis and product return and exchange services are offered within the warranty period, with lifelong maintenance supported.