Our company has recently commenced the gear-milling phase for a large, heavy-duty gear wheel customized for a South American client. With an outer diameter of 2000 mm and a module of 20M, the gear is crafted from 42CrMo alloy steel. Designed for transmission systems in heavy-duty equipment, it demands high load-bearing capacity and presents significant machining challenges.
The workpiece has already undergone rough turning, non-destructive testing (NDT), hardness inspection, and quenching and tempering (heat treatment). Through multiple rounds of rigorous inspection, we have verified its internal microstructure and mechanical properties, effectively mitigating the risk of thermal deformation-a common issue with large-scale components. The current milling process utilizes a floor-type boring machine paired with a large rotary table; the rotary table ensures precise indexing, guaranteeing both the accuracy of the large-module tooth profile and the consistency of the tooth surfaces.
Gears of such large diameter and module impose stringent requirements on equipment rigidity, fixture positioning, and the control of cutting parameters. Our chosen process leverages the adaptability of the floor-type boring machine, successfully overcoming challenges related to the clamping of massive components and the management of cutting vibrations. The project is progressing steadily, serving as another demonstration of our manufacturing capabilities for large-scale transmission components destined for the overseas heavy-industry market, while further solidifying the foundation for our ongoing service to clients in South America's heavy-industry sector.
