Research on processing technology of contour tooth spiral bevel gear
September 04 20:00:22, 2025
With the continuous improvement of China's highway infrastructure and the evolving demands of the logistics industry, heavy-duty truck axle loads are now expected to handle high load, high torque, lightweight design, low noise, wide speed ratios, long service life, and cost efficiency. As a result, single-stage deceleration contour gear spiral bevel gears have become the preferred choice for today’s heavy-duty rear axles due to their high transmission efficiency, large load capacity, low fuel consumption, and cost-effectiveness.
To meet these requirements, our company has developed various series of small-speed ratio and high-torque spiral bevel gears. For example, the 469 model offers extension ratios such as 8:37, 9:37, 10:37, 11:37, 12:37, and 13:37. As the number of teeth on the driving gear increases, the input torque rises while maintaining a constant output torque, which places higher demands on the strength of the driving gear. Therefore, we select 22CrMoH steel for both the main and driven gears, considering its mechanical properties, manufacturing costs, and raw material prices.
**Blank Quality Control**
22CrMoH is a Cr-Mo high-strength gear steel, equivalent to Japan's SCM822H. Its chemical composition is shown in Table 1. Due to its high carbon and alloy content, it presents challenges in hardenability and band structure control. During austenitizing, the hardenability depends on carbon content and alloying level. Dendritic segregation from alloy elements and uneven carbon distribution can form strip or secondary strip structures after rolling and heat treatment.
To ensure the wear resistance, fatigue strength, and impact resistance of the gear, the blank quality must be strictly controlled. Variations in raw materials, smelting processes, and alloy components across different steel mills lead to significant performance differences in 22CrMoH. When selecting the material, factors like hardenability, carburizing layer plasticity, tempering dimensional stability, overheat sensitivity, deformation resistance, and impact toughness must be considered. The chemical composition, oxygen content, inclusions, low-fold structure, grain size, hardenability, and band structure should all be tightly controlled.
Key specifications include:
1. Chemical composition meeting the standards in Table 1.
2. Oxygen content ≤ 0.0015%.
3. Non-metallic inclusions inspected by GB10561 standard, with A≤2.5, B≤2, C≤1, D≤1.
4. Grain size according to YB/T5148, with austenite grain size ≥ 5 grades after air-cooling at 930°C × 6h.
5. Hardenability test per GB/T225, with end quenching hardness of 33–38 HRC and maximum deviation ≤4 HRC.
6. Low-fold structure inspected by GB/T3077 and GB/T1979, with general looseness ≤3.
7. Band structure ≤3 grades per GB/T13299.
**Spiral Bevel Gear Classification and Processing**
1. **Classification and Current Status of Spiral Bevel Gears**
Automotive drive axle spiral bevel gears are mainly designed using two types of teeth: contour teeth and shrinking teeth, also known as Olecon and Gleason teeth. In China, shrinking teeth are widely used due to their low contact area sensitivity, allowing them to meet noise and contact requirements even with processing and assembly errors. However, with increased international technical exchanges and the introduction of advanced foreign equipment, contour teeth are gaining popularity in China.
Contour teeth offer advantages such as high processing efficiency, dry cutting technology, reduced transportation waste, and lower noise levels. However, they are sensitive to machining and assembly accuracy, making them unsuitable for high-precision applications. Despite this, they are increasingly being adopted globally.
2. **Spiral Bevel Gear Digital Closed Loop System**
Leading manufacturers like Klinberg-Olikon (Germany) and Gleason (USA) provide complete digital closed-loop systems for spiral bevel gear production. These systems allow for the conversion between contour and shrinking teeth, with software like KIMOS and Gleason enabling precise design, processing, and measurement.
Using these tools, designers can adjust contact zones, tooth shape, and other parameters to achieve optimal gear performance. Equal strength or life calculations are often performed to ensure balanced performance between the driving and driven gears.
Our company uses Gleason software for equal-life design and converts it via KIMOS software. We employ the Gleason Phoenix II 600HC milling machine for dry cutting, the Klingberg P65 testing center for precision measurement, and Olympus B27 grinders for tool accuracy. This integrated system ensures three-level machining accuracy and real-time data transmission, reducing human error and enhancing automation.
3. **Dry Cutting Technology**
Dry cutting is a major innovation in spiral bevel gear processing, improving efficiency, reducing costs, and eliminating pollution. Our tests show that material hardness and uniformity significantly affect tool life. By using domestic carbide tools with titanium aluminide coatings, we achieve high tool durability and cost efficiency.
For example, the 469 driven gear can be processed at 200m/min linear speed, with each grinding cycle lasting 12 minutes and producing over 150 units. This solution effectively addresses the issue of unacceptably high costs associated with foreign technologies.
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