| Customization: | Available |
|---|---|
| Application: | Motor, Electric Cars, Motorcycle, Machinery, Marine, Toy, Agricultural Machinery, Car |
| Hardness: | Hardened Tooth Surface |
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The manufacturing process of large gears, especially giant gears with a diameter of 2 meters or more, is a complex and highly specialized process. It covers a series of steps from raw material selection to final inspection, and requires strict quality control and adherence to specific standards to ensure its performance and lifespan. The following are the main processes, precautions, and key points of quality control in the manufacturing of large gears. The manufacturing process usually listed as below:
Material Selection:
Choose suitable steel according to the usage environment and load requirements, usually using high-quality alloy steel. Considering the size effect, special attention may need to be paid to the uniformity and purity of the material.
Forging:
For large gears, preliminary forming is usually carried out through free forging or die forging. During the forging process, temperature, pressure, and cooling rate must be strictly controlled to ensure the optimization of internal structure and reduce defects.
Heat Treatment:
including processes such as normalizing, quenching, and tempering, aimed at improving the mechanical properties of materials, such as hardness, strength, and toughness. The temperature control, cooling rate, and uniformity during the heat treatment process are crucial for the quality of the final product.
Rough Machining:
Precision Machining:
Precision machining for big gears includes processes like grinding and shaving to achieve the high precision and surface smoothness essential for design specifications. Grinding involves using precision grinders to finely hone the tooth profile, ensuring exact dimensions and a smooth surface finish. Shaving refines the tooth shape further, correcting minor inaccuracies from the grinding stage and ensuring perfect meshing between teeth. These steps are crucial for maximizing transmission efficiency and stability. Operators meticulously adjust machine settings based on specific gear parameters and use advanced measuring tools to monitor accuracy throughout. This meticulous process not only enhances performance but also extends the gear's lifespan under demanding operational conditions, ensuring reliable and efficient operation. Strict quality control measures are applied to meet design standards, with CNC technology facilitating consistent and repeatable results.
Testing and Inspection:
Using various non-destructive testing methods (such as ultrasonic testing, magnetic particle testing) to inspect internal and surface defects; And verify the product quality through hardness testing, dimensional accuracy measurement, and other methods.
Key Points:
Size Control:
Due to the large size of the large gear, any small error can lead to assembly problems or operational failures.
Stress Analysis:
In the design phase, it is necessary to fully consider the stress distribution under actual working conditions to avoid failure caused by local overload.
Temperature Management:
Both forging and heat treatment stages require precise temperature control to prevent material performance degradation.
Quality Control and Standards
ISO 6336: International standards are used to calculate the load-bearing capacity of gears, including fatigue strength and wear life prediction.Throughout the entire manufacturing process, it is necessary to strictly follow the above standards and combine modern manufacturing technologies, such as the application of CNC machine tools, to improve production efficiency and product consistency. In addition, continuous monitoring and improvement of production processes are also important measures to ensure the quality of large gears.
| Diameter | ≤10 meters |
| Module | ≤45 |
| Material | 17CrNiMo6,AIS4140, 40CrNiMo, Bronze or other customized Material |
| Process | Cast Alloy Steel, Cast Carbon Steel, Forged Alloy Steel, Forged Carbon Steel |
| Heat treatment | Quenching & Tempering, Normalizing & Tempering, Carburizing & Quenching & Tempering |
| Weight | 1-10tons |
| Structure From | Integrated, Half to Half, Four Pieces and More Pieces |
| Tooth Form | Annular Gear, Outer Gear Ring |
| Application | Cement, electric power, metallurgy, chemical, non-metallic mining and other industries |
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.
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.
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