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Custom Gear Shaft Forging | High-Precision Transmission Shaft Manufacturer
Gear shafts (also known as shaft gears or gear-shaft assemblies) are integrated transmission components that combine gear and shaft into a single unit, widely used in automotive transmissions, industrial reducers, construction machinery drive axles and wind turbine gearboxes. Compared to separate gear + shaft configurations, gear shafts offer significant advantages including compact structure, high transmission accuracy and excellent load-bearing capacity.
The manufacturing process route for gear shafts is: material selection → forging (closed-die forging or open-die free forging) → normalizing → rough machining → finish turning → gear hobbing/shaping → carburizing and quenching → gear grinding → journal grinding → final inspection. Materials include 20CrMnTi, 20CrMo, 42CrMo alloy structural steels or imported grades such as SAE 8620/4320. The forging process ensures complete grain flow distribution to enhance fatigue resistance. After carburizing and quenching treatment, tooth surface hardness reaches HRC 58-62 with effective case depth of 0.8-1.5mm; journals undergo medium-frequency induction hardening achieving hardness HRC 52-56.
The critical gear grinding process utilizes CNC form gear grinding machines, achieving tooth accuracy up to DIN Grade 5. Journal grinding precision is controlled to ≤h6 with roundness ≤0.005mm. Each gear shaft undergoes magnetic particle inspection (MT), ultrasonic testing (UT) and tooth profile/lead inspection before delivery, ensuring zero-defect shipment. We can manufacture gear shafts with lengths ranging from 100mm to 2,000mm and modules from 1 to 16. PPAP documentation and SPC process capability analysis reports are available for batch orders.
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