The process of creating Klingelnberg gear customization begins with detailed engineering analysis. Unlike standard gears, which force the designer to adapt their system to existing dimensions, a customized solution starts with the customer’s actual operating conditions: torque, speed, center distance, shaft angle, duty cycle, and available lubrication. Klingelnberg’s engineers use KIMoS (Klingelnberg Integrated Manufacturing of Spiral Bevel Gears), a powerful design and simulation software, to generate a digital twin of the gear set. Within this virtual environment, they optimize macro-geometry parameters such as tooth count, spiral angle, face width, and profile crowning.
Klingelnberg Gear Customization
Specification
Module
3
Application
Heavy-duty truck
Material
20MnCr5
Heat Treatment
Case-hardened
Accuracy
DIN 8
Customized Klingelnberg Bevel Gear: Precision, Performance, and Reliability
In modern mechanical power transmission, few components are as essential—or as demanding—as the bevel gear. When designers need to change the direction of power between intersecting shafts while maintaining smooth, quiet, and efficient operation, the spiral bevel gear is often the solution of choice. Among the world’s most respected names in gear manufacturing technology, Klingelnberg stands out for its advanced cutting, grinding, and measuring systems. However, beyond selling machinery, Klingelnberg also offers a contract manufacturing service that produces a customized Klingelnberg bevel gear tailored to specific customer requirements. This service bridges the gap between off-the-shelf limitations and full in-house production, providing engineered solutions for applications ranging from heavy-duty axles to high-speed electric drives.
Once the design is validated, manufacturing proceeds on Klingelnberg’s own advanced machine tools, including the C-Series and G-Series lines. Depending on the required quality grade and batch size, the shop may choose formate or face-hobbing processes, and for high-precision gears, subsequent grinding or lapping. A key advantage of working with Klingelnberg is the integrated Closed Loop concept: after cutting, the gear is measured on a Klingelnberg precision measuring center, and any deviations are automatically fed back via KOMET software to the cutting or grinding machine for correction. This feedback loop achieves quality levels up to DIN 1 or AGMA Q15—standards typically reserved for aerospace and motorsport applications. Heat treatment (e.g., carburizing or nitriding) and surface finishing (e.g., shot peening or phosphate coating) are then applied according to the customer’s specifications. For small to medium volumes—where purchasing a dedicated bevel gear cutting line would be uneconomical—outsourcing to a certified Klingelnberg contract shop is both cost-effective and technically superior.
Production process
6-Step Production Process
Forging
Turning
Rough Cutting
Heat Treatment
ID & OD Grinding
Hard Cutting
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.
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.
Rough Cutting
Rough Cutting is the first and fast-cutting stage for gears, rapidly removing bulk material to bring it close to final shape with high depth of cut and speed.
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 & OD 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.
Hard Cutting
Hard Cutting is a most common high precision method for klingelnberg bevel gears which is in order to replace or reduce grinding by performing finishing operations, it is a dry or near-dry process.
Inspection
Strict Quality Inspection
Dimension Inspection
Material Testing
Hardness Inspection
Heat Treatment Testing
Accuracy Testing
Meshing Testing
Dimension Inspection
Material Testing
Hardness Inspection
Heat Treatment Testing
Accuracy Testing
Meshing 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
Out Package
Carton
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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