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OEM Gear Custom Helical Gear

This helical gear uses AISI 8620, a low-carbon nickel-molybdenum carburized steel. After carburizing, the surface layer can easily achieve a high hardness of 58-62 HRC, making the tooth surface particularly wear-resistant and less prone to wear and pitting during high-speed rotation. The internal core of the custom helical gear has excellent toughness, capable of withstanding the rapid acceleration and braking of a car, preventing breakage at the gear root and effectively extending the gear’s lifespan.

Furthermore, the helical gear’s inherent spiral inclined tooth structure allows for gradual contact during gear meshing, with multiple teeth sharing the force, reducing impact and vibration during operation and minimizing noise.

Specification
Module
3
Application
Electric vehicles
Material
8620
Heat Treatment
Case hardened 58-62HRC
Accuracy
Grade 7
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Helical Gear For Electric Vehicles

 

Helical gears are widely used in the new energy vehicle sector. New energy motors typically operate at speeds between 15,000 and 20,000 rpm, and the vehicles have extremely high NVH (noise, vibration, and harshness) requirements. Helical gears perfectly meet the two core needs of electric vehicles:

Firstly, helical gears produce less noise and vibration compared to spur gears. The progressive meshing of the helical gear teeth allows multiple pairs of teeth to share the load simultaneously, resulting in lower noise and vibration.

Secondly, helical gears can handle higher torque, making them suitable for heavy-load starts in electric vehicles. With the same outer diameter and module, helical gears have a longer effective contact tooth length and more meshing tooth pairs than spur gears. This results in more even stress distribution on the tooth surface, stronger resistance to pitting, and less susceptibility to tooth cracking. They can withstand the large torque surge during the initial start-up of an electric vehicle, extending the lifespan of the reducer.

Production process

6-Step Production Process

Forging
Turning
Gear Cutting
Heat Treatment
ID & OD & Surface Grinding
Tooth Grinding
1
2
3
4
5
6
High-precision-forging-gear-production-process-Belon-China-manufacturer

Forging

When gears need high performance that needs to withstand high loads, high stress, impact loads or fatigue loads, forgings are suggested to use. Forging allows metal fibers to be continuously distributed along the gear profile, significantly improving root strength and fatigue life.
High-precision-turning-gear-production-process-Belon-manufacturer

Turning

This is the process of cutting and shaping solid materials into precise parts. It uses tools like lathes, mills, and drills to remove excess material. Machining transforms a simple block of metal into a finished, functional component.
Gear-cutting-large-spur-gear-for-gearboxes-gear-manufacturing-process

Gear Cutting

Gear Cutting includes all processes to create gear teeth after rough or fine machining. It shapes teeth to ensure smooth and efficient power transfer for performance, strength and cost efficiency.
Gear-Heat-treatment-gear-manufacturing-process-gear-supplier-Belon

Heat Treatment

Gears need to be running with two gears or above two gears, that makes them easy to be worn-out. That’s why most types of gears need to be harden through heat treatment.
ID-Grinding-Gear-Manufacturing-Process-Gear-Supplier-Belon

ID & OD & Surface Grinding

ID grinding, OD grinding, Surface grinding are all belonging to CNC grinding which are the foundational precision abrasive machining processes used to achieve exceptional dimensional accuracy and surface finishes, especially on hardened materials.
Gear-Grinding-Gear-Manufacturing-Company-Gear-Supplier-Belon

Tooth Grinding

Tooth Grinding are the final processes are applied after heat treatment to correct distortion, improve geometry, and achieve the final surface finish necessary for quiet, efficient power transmission.
Inspection

Strict Quality Inspection

Dimension-Inspection-Gear-Quality-Control-Spur-Gear-Manufacturing-Company-Belon

Dimension Inspection

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Material Inspection

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Heat Treatment Testing

UTMT-testing-Gear-Quality-Test-Gear-Manufacturing-Company-Belon

UT & MT Testing

Meshing-testing-Gear-Quality-Test-Gear-Manufacturing-Process-Belon

Meshing Testing

Accuracy-testing-Gear-Quality-Test-Gear-Manufacturing-Company-Gear-Supplier-Belon

Accuracy Testing

Dimension-Inspection-Gear-Quality-Control-Spur-Gear-Manufacturing-Company-Belon

Dimension Inspection

Material-Inspection-Gear-Quality-Gear-Manufacturing-Company-Gear-Supplier-Belon

Material Inspection

Heat-treatment-testing-gear-manufacturing-quality-control-process-Belon

Heat Treatment Testing

UTMT-testing-Gear-Quality-Test-Gear-Manufacturing-Company-Belon

UT & MT Testing

Meshing-testing-Gear-Quality-Test-Gear-Manufacturing-Process-Belon

Meshing Testing

Accuracy-testing-Gear-Quality-Test-Gear-Manufacturing-Company-Gear-Supplier-Belon

Accuracy Testing

Packages

Professional Packaging Safe Arrival

Customized cost-effective packages for products protection. We select multi-model solutions, combining air, sea, or land freight for the optimal balance of cost, speed, and reliability.
Inner-Package-Gear-Product-Gear-Manufacturing-Company-Gear-Supplier-Belon

Inner Package

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Out Package

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Carton

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Wooden Package

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Your Precision
Transmission Partner

Do you have drawings to be implemented, or problems to be solved? Please feel free to contact us. From initial inquiry and technical specification confirmation to production and delivery, our dedicated team will provide you with one-on-one service, ensuring that every step meets your stringent requirements for precision.
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