Helical Gear Manufacturing Services
Precision-engineered helical gears for superior performance, reduced noise, and enhanced load capacity. Custom solutions for automotive, industrial, and transmission applications.
Advanced Helical Gear Solutions
Helical gears represent the pinnacle of modern gear technology, offering superior performance characteristics compared to traditional spur gears. With their angled teeth design, helical gears provide smoother operation, reduced noise levels, and enhanced load-carrying capacity, making them the preferred choice for high-performance applications across automotive, aerospace, and industrial sectors.
Superior Performance
Higher load capacity and smoother operation than conventional gear systems
Reduced Noise
Gradual tooth engagement minimizes noise and vibration levels
Custom Design
Tailored solutions for specific application requirements and constraints
Helical Gear Product Range
External Helical Gears
Standard external helical gears featuring angled teeth for parallel shaft applications. These gears provide smooth power transmission with reduced noise and vibration compared to spur gears.
- Module range: 0.5 to 25
- Helix angles: 15° to 45°
- Precision grades: DIN 5-10
- Maximum diameter: 2000mm
Internal Helical Gears
Internal helical gears designed for planetary gear systems and compact applications. These gears mesh with external pinions to create efficient, space-saving transmission solutions.
- Internal diameter: 50-1500mm
- High precision manufacturing
- Compact design solutions
- Planetary applications
Double Helical Gears
Herringbone-style gears with opposite helix angles that eliminate axial thrust forces. Ideal for high-power applications requiring maximum stability and load distribution.
- Eliminates axial thrust
- High power transmission
- Superior load distribution
- Heavy-duty applications
Crossed Helical Gears
Specialized helical gears for non-parallel shaft applications. These gears enable power transmission between shafts at various angles, providing design flexibility for complex machinery.
- Non-parallel shaft transmission
- Angular flexibility
- Complex geometry solutions
- Specialized applications
Precision Manufacturing Process
Advanced Cutting Technologies
Our state-of-the-art manufacturing facility employs the most advanced helical gear cutting technologies to ensure precision, consistency, and superior quality in every gear we produce.
Gear Hobbing
High-precision CNC hobbing machines with advanced control systems for consistent tooth geometry and surface finish.
Gear Shaping
Precision shaping for internal gears and complex geometries that cannot be achieved through hobbing.
Gear Grinding
Post-hardening grinding operations for achieving the highest precision grades and surface quality.
Heat Treatment
Controlled heat treatment processes including carburizing, quenching, and tempering for optimal hardness distribution.
Helical Gears vs Spur Gears
Helical Gear Advantages
- Smoother and quieter operation
- Higher load carrying capacity
- Gradual tooth engagement
- Reduced vibration and noise
- Better for high-speed applications
- Higher contact ratio
Spur Gear Characteristics
- Simple and economical design
- No axial thrust forces
- Easier manufacturing process
- Lower manufacturing cost
- Suitable for low-speed applications
- Direct power transmission
Key Performance Metrics
Technical Specifications
| Parameter | Specification | Tolerance | Standard |
|---|---|---|---|
| Module Range | 0.5 - 25 mm | ±0.01 mm | DIN 3960, ISO 1328 |
| Helix Angle | 8° - 45° | ±5 arcmin | DIN 3960 |
| Pressure Angle | 14.5°, 20°, 25° | ±2 arcmin | ISO 53, DIN 867 |
| Accuracy Grade | DIN 5 - DIN 10 | As per DIN 3962 | DIN 3962, AGMA 2000 |
| Maximum Diameter | Up to 2000 mm | ±0.02 mm | ISO 1101 |
| Face Width | 5 - 500 mm | ±0.05 mm | DIN 3962 |
| Surface Hardness | 58-65 HRC | ±2 HRC | ISO 6508 |
| Surface Roughness | Ra 0.4 - 1.6 μm | ±10% | ISO 4287 |
Material Options
Carbon Steel
AISI 1045, C45, S45C for general purpose applications with good strength and machinability.
- • Cost-effective solution
- • Good mechanical properties
- • Wide availability
- • Heat treatable
Alloy Steel
AISI 4140, SCM440, 42CrMo4 for high-strength and heavy-duty applications.
- • High strength and toughness
- • Excellent hardenability
- • Fatigue resistance
- • Automotive grade
Stainless Steel
316, 17-4PH for corrosion-resistant and food-grade applications.
- • Corrosion resistance
- • Hygienic properties
- • High temperature resistance
- • FDA compliant options
Aluminum Alloy
6061-T6, 7075-T6 for lightweight and aerospace applications.
- • Lightweight design
- • Good corrosion resistance
- • Excellent machinability
- • Aerospace applications
Heat Treatment Options
Carburizing
Case hardening for surface wear resistance while maintaining core toughness
Induction Hardening
Selective hardening of tooth surfaces for improved wear resistance
Nitriding
Surface treatment for enhanced hardness and corrosion resistance
Industry Applications
Automotive Industry
Helical gears are extensively used in automotive transmissions, differentials, and transfer cases for smooth power delivery and reduced NVH levels.
- • Manual and automatic transmissions
- • Differential assemblies
- • Transfer cases and PTOs
- • Electric vehicle drivetrains
- • Steering systems
Industrial Machinery
Critical components in industrial gearboxes, reducers, and drive systems requiring high reliability and precision.
- • Speed reducers and gearboxes
- • Conveyor systems
- • Machine tool drives
- • Mixing and agitation equipment
- • Printing machinery
Aerospace & Defense
Lightweight, high-strength helical gears for aircraft engines, landing gear, and flight control systems.
- • Aircraft engine gearboxes
- • Helicopter transmissions
- • Landing gear mechanisms
- • Actuator systems
- • Satellite mechanisms
Marine Applications
Robust helical gears designed for marine propulsion systems and deck machinery in harsh saltwater environments.
- • Marine gearboxes
- • Propulsion systems
- • Winches and cranes
- • Steering gear
- • Anchor windlass
Power Generation
High-capacity helical gears for wind turbines, hydroelectric plants, and thermal power generation equipment.
- • Wind turbine gearboxes
- • Hydroelectric generators
- • Steam turbine drives
- • Solar tracking systems
- • Generator drives
Robotics & Automation
Precision helical gears for robotic joints, servo drives, and automated manufacturing systems requiring high accuracy.
- • Robot joint actuators
- • Servo motor gearheads
- • Linear actuators
- • Automation systems
- • Precision positioning
Quality Assurance & Certifications
Rigorous Quality Control
Our commitment to quality excellence ensures that every helical gear meets the highest industry standards through comprehensive testing and inspection procedures.
Inspection Equipment
Frequently Asked Questions
Helical gears offer several significant advantages over spur gears: they operate more smoothly and quietly due to gradual tooth engagement, can handle 30-50% higher loads, produce less vibration, and are better suited for high-speed applications. The angled teeth create a higher contact ratio, resulting in improved power transmission efficiency and reduced wear.
Lead times vary depending on complexity and quantity. For prototype quantities (1-10 pieces), typical lead time is 2-3 weeks. For production quantities (100+ pieces), lead time ranges from 4-8 weeks. Rush orders can often be accommodated with expedited processing. Complex geometries or special materials may require additional time.
We can achieve precision grades from DIN 5 to DIN 10, with DIN 6-7 being our standard offering for most applications. For critical applications requiring the highest precision, we can achieve DIN 5 grade through precision grinding operations. The achievable accuracy depends on the gear size, module, and manufacturing process used.
Yes, we manufacture both left-hand and right-hand helical gears according to your specifications. The hand of the helix is determined by your application requirements and mating gear considerations. We can also manufacture double helical (herringbone) gears that eliminate axial thrust forces for high-power applications.
For automotive transmission applications, we typically recommend carburizing grades such as AISI 8620, 4320, or equivalent. These materials provide excellent case hardness for wear resistance while maintaining core toughness. For high-performance applications, we also offer premium grades like AISI 9310 or custom alloy steels with specific heat treatment protocols.
Yes, we offer comprehensive gear design and engineering services. Our team can assist with gear train optimization, stress analysis, material selection, and manufacturing feasibility studies. We use advanced software for gear design and can provide detailed engineering drawings, 3D models, and manufacturing recommendations for your specific application.
We accommodate orders from single prototype pieces to high-volume production runs. For prototypes and small quantities (1-50 pieces), we offer flexible manufacturing options. For production quantities, MOQ typically starts at 100 pieces, but this can vary based on the complexity and size of the gears. Contact us to discuss your specific requirements.
We maintain quality through rigorous process controls including SPC monitoring, 100% inspection of critical dimensions, CMM measurement verification, and statistical process control. Our ISO 9001:2015 certified quality system ensures consistent procedures, and we provide detailed quality reports including dimensional inspection data, material certifications, and traceability documentation with each shipment.