Ultra-Precision Machining for Heavy-Duty Gearbox & Power-Transmission Components
Driving Construction Machinery and Smart Automation with Micron-Level Accuracy
Modern excavators, concrete pumps, tunnel borers, and high-speed automated cells all rely on compact gearboxes and power-transmission assemblies to convert motor output into controlled, high-torque motion. A single micron of error in these parts can amplify into vibration, heat build-up, and premature failure on site—where downtime is counted in thousands of dollars per hour.
1. Engineering & Machining Challenges
| Challenge | Why It Matters | Typical Spec We Achieve |
|---|---|---|
| Tooth-profile accuracy on helical, spur & planetary gears | Minimises backlash, NVH and power loss | DIN 6 / AGMA 10 (profile & lead error ≤ 7 µm) |
| Cumulative tolerance stack-up in multi-stage geartrains | Keeps bearing preload & meshing alignment stable | Axial error ≤ ±0.01 mm over 350 mm stack |
| Post-heat-treat distortion of large gears & shafts | Ensures concentricity after carburising to 62 HRC | Corrected to ≤ 0.005 mm TIR by hard-turning |
| Oil-channel integrity in thin-wall housings | Guarantees constant lubrication & temperature control | Cross-hole positional error ≤ ±0.05 mm, burr-free |
| Dynamic balance for high-speed servo gearboxes | Reduces vibration at 6 000–12 000 rpm | ISO G 2.5 balancing on rotors up to Ø250 mm |
2. Material Strategy & Surface Engineering
| Material Grade | Typical Component | Treatment & Finish |
|---|---|---|
| 20CrMnTi / 8620H | Gears & planet carriers | Case-carburised 0.9 mm; tooth grinding & shot peening |
| 42CrMo4 / 4140 | Input/output shafts | Quench & temper to 38–42 HRC, hard-turned journal OD Ra 0.2 µm |
| EN GJS-700 Ductile Iron | Gearbox casings | Stress-relieved, precision-milled faces, epoxy primer |
| 7075-T6 Aluminum | Servo gear reducers | Hard anodised, jig-bored bearing seats ± 0.003 mm |
| 17-4 PH Stainless | Food-grade automation drives | H900 age-hardening, electropolished cavity surfaces |
Advanced coatings—DLC, CrN, MoS₂ dry-film—are available for extreme wear or lubrication-free applications.
3. Integrated Manufacturing Workflow
- Simulation-driven DFM – Our engineers import STEP/Parasolid files, run finite-element & gear-mesh simulations, then refine tolerances before cutting metal.
- Rough Machining – Horizontal CNC lathes remove 70 % of stock with in-process probing to stabilise heat input.
- 5-Axis Finish Milling – DMG Mori & Mikron centers cut housing ports, spiral oil galleries, and sensor bosses in one clamp.
- Heat Treatment & Cryogenic Stress-Relief – On-site vacuum furnaces followed by –190 °C cryo soak to minimise retained austenite.
- Hard-Turning & Gear Grinding – Studer grinders and Kapp-Niles profile grinders hit sub-5 µm runout; superfinishing reduces Ra to 0.05 µm.
- Dynamic Balancing & Helium-Leak Testing – Schenck rigs certify ISO G 2.5 balance; mass-flow rigs verify oil-channel sealing at 10 bar.
- 100 % Digital QA – Zeiss PRISMO CMM + Klingelnberg P26 gear analyser; SPC data logged to customer portal in real time.
4. Equipment Highlights
- 4× Mazak INTEGREX i-300 multi-tasking turn-mill (Ø650 mm × 1 500 mm)
- 2× Kapp-Niles ZX-1000 form & generating grinders (module 0.5–10)
- Schenck HM 20 dynamic balancers (up to 12 000 rpm)
- Zeiss PRISMO ultra CMM (0.9 µm + L/350) with rotary table for full gear-mesh scanning
- Vacuum carburising furnace 1 000 kg load, uniformity ±5 °C
5. Global Success Stories
| Client & Region | Component Supplied | Value Delivered |
|---|---|---|
| German tunnelling-machine OEM | Dual-stage planetary gear sets (DIN 6) | 30 % noise reduction, MTBF ↑ 8 000 h |
| U.S. autonomous dozer startup | Aluminum servo-gear housings, ±0.01 mm flatness | 15 % weight saving, assembly time –20 % |
| Japanese robotics integrator | High-speed harmonic-drive input shafts (Ra 0.1 µm) | Zero vibration at 10 000 rpm endurance test |
| Brazilian concrete-pump maker | Large helical ring gears Ø820 mm, module 8 | Field downtime ↓ 25 % over previous supplier |
6. Partner With a Micron-Focused Team
From prototype to 10 000-piece volume, we combine simulation-led engineering, vertically integrated heat treatment, and nanometer-grade inspection to keep your machinery turning—silently, efficiently, and for millions of cycles.
📧 Share your 2D/3D files for a 24-hour DFM review and quotation.