Case Studies

Typical Manufacturing Projects

Representative gear and gear shaft projects across industries — showing the range of materials, precision, and volumes we handle.

Agricultural Machinery

High-Volume Carburized Gears for Farm Equipment

Annual-volume production of transmission gears for mid-size tractors and combine harvesters.

The Challenge

The customer needed a steady supply of carburized gears with consistent hardness across batches of 5,000+ pieces per order. Gear tooth wear under heavy field loads was the main failure mode, and previous suppliers had inconsistent heat treatment results.

Our Approach

We standardized on 20CrMnTi alloy steel with controlled carburizing (0.6–0.9mm case depth, 58–62 HRC surface hardness). Each batch is sampled for hardness profile and tooth profile inspection before shipment. We maintain a 30-day rolling raw-material buffer to keep lead times stable.

Outcome

Consistent batch-to-batch quality with 99.2% first-pass acceptance. The customer has reordered for three consecutive years with zero field-failure returns related to gear hardness.

20CrMnTiCarburized 58-62 HRCIT7 accuracy5,000+ pcs/batch Hobbing + shaving

Industrial Reducers

Precision Ground Helical Gears for Gearboxes

Low-noise, high-precision helical gear sets for industrial speed reducers used in conveyor and material handling systems.

The Challenge

The gearbox design required low transmission noise (<65 dB at rated load) and high positional accuracy. Standard hobbing alone could not meet the tooth profile tolerance required for smooth meshing.

Our Approach

We produce the gears via hobbing followed by heat treatment (quenching + tempering) and finish grinding on a CNC gear grinding machine. Tooth profile and lead are verified on a CNC gear measuring center, with a full inspection report shipped with each batch.

Outcome

Tooth profile accuracy reaches IT5–IT6 after grinding. The assembled gearboxes consistently meet the customer's noise target, and rework rates dropped below 1%.

42CrMoQuenched + temperedIT5-IT6 groundCNC gear inspectionLow-noise design

New Energy Equipment

Integrated Gear Shafts for Solar Tracking Systems

Custom gear shafts combining gear cutting and precision shaft machining in a single setup for solar tracker drive units.

The Challenge

The part required both gear teeth and precision bearing journals on the same shaft, with strict concentricity between the gear pitch circle and the bearing surfaces. Misalignment would cause premature wear in the tracking drive.

Our Approach

We machine the shaft journals first, then cut the gear teeth in the same fixturing to guarantee concentricity. Final inspection includes runout measurement on a CMM and gear tooth inspection. Parts are shipped with individual inspection records.

Outcome

Concentricity within 0.01mm consistently. The customer reduced assembly rework from 8% to under 1% after switching to our integrated gear shaft production.

40CrIntegral gear shaft0.01mm concentricityCMM inspectedSingle-setup machining

Request for quote

Move from technical review to a clear gear manufacturing RFQ.

Send drawings, material requirements, quantity, tolerance notes, and inspection expectations. Proshine will review the manufacturing scope before quotation.

Submit Gear RFQ