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Custom Zerol Bevel Gear

For an ordinary Spiral Bevel Gear, the teeth are inclined along the face width direction, with a spiral angle of 20°–35°. Therefore, when a pair of teeth engage, they decompose a portion of the force into an axial component → the shaft is pushed in one direction → thrust bearings must be arranged.

The approach of Zero Degree / Zerol is: The tooth trace is still made into a curved arc shape (this comes from the Gleason face milling process). But the spiral angle is symmetrically brought back to 0° (the tangent at the midpoint of the tooth trace is perpendicular to the radial direction).

Result:​ The contact behavior of the teeth gains the gradual/progressive nature of a curved tooth, but the axial projection of the forces is approximately at the level of a straight bevel gear.

Essentially, it is a bevel gear that is “bent in shape, but not twisted in angle.”

Specification
Module
3.5
Application
Aircraft engine accessory drive
Material
M50
Heat Treatment
Carburizing HRC 58-63
Accuracy
DIN 5–6
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Zerol Bevel Gear Used In Aviation

 

Zerol is not the (mainstay) for main reduction/main transmissions in aviation — those positions belong to true spiral bevel gears, planetary gears, or hypoid solutions. Instead, it is concentrated in accessory drives, auxiliary mechanisms, and space-extremely-constrained right-angle transmission nodes — its core value remains the same: “the progressive engagement of a spiral bevel gear + the zero axial thrust of a straight bevel gear.”

Engine Accessory Gearbox

This is the most classic and “legitimate” application of Zerol in aviation.

Power from the turbine engine’s main shaft must be branched off to drive:

  • Generator / IDG (Integrated Drive Generator)
  • Hydraulic pump
  • Fuel pump
  • Oil pump
  • Starter / air turbine starter drive train

Within these drive chains, there are numerous 90° intersecting-axis turning points, with the following constraints:

  • Extremely tight space (housing wall thickness, bearing span, radial envelope are all calculated down to the millimeter)
  • Large thrust bearing structures cannot be arbitrarily added (weight, space, and lubrication do not permit it)
  • Rotational speeds can be very high (accessory takeoffs often go through speed increases, reaching 10,000+ rpm)
  • Noise and vibration excitation must be controlled
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Production process

6-Step Production Process

Forging
Turning
Gear Milling
Heat Treatment
ID & OD Grinding
Tooth Grinding
1
2
3
4
5
6
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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.
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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.
High-precision-gear-milling-production-process-gear-manufacturer-belon

Gear Milling

Gear Milling is a gear cutting process that used a rotating from cutter shaped to match the exact space between two gear teeth is plunged into the gear blank. After cutting one tooth space, the blank is indexed to the next position .
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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.
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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.
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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

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Dimension Inspection

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Material Testing

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Hardness Inspection

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Heat Treatment Testing

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Roughness Testing

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Accuracy Inspection

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Meshing Testing

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Dimension Inspection

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Material Testing

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Hardness Inspection

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Heat Treatment Testing

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Roughness Testing

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Accuracy Inspection

Meshing-Testing-Gear-Manufacturing-Quality-Control-Process-Belon

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.
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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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