Precision Gear Machining Services for Forged Gear Components
At Weforging Manufacturing, we specialize in precision gear machining services for industrial and OEM applications. Our capabilities combine hot forging and ring forging of gear blanks with advanced CNC gear machining, including turning, hobbing, shaping, grinding, and surface treatments.
By integrating forging and machining under one manufacturing system, we deliver gears with optimized grain structure, stable dimensional accuracy, and reliable performance. We support OEM customers across Europe and North America with custom gear solutions tailored to precise technical standards.
What Is Gear Machining?
Gear machining is a complete manufacturing process that transforms forged or cast gear blanks into finished gears with precise tooth profiles and tight dimensional tolerances. The workflow typically includes turning, hobbing, shaping, broaching, grinding, and heat treatment. Each step enhances gear strength, surface finish, and overall performance, ensuring reliable operation in transmissions, drive systems, and heavy machinery.
Gear Types We Manufacture
Precision Sun Gears – For planetary gear systems, ensuring accurate torque transfer and long service life.
Gear Shafts – Manufactured to ISO-certified standards for reliable power transmission.
Pinion Gears – Custom forged and CNC machined for smooth engagement and durability.
Internal Ring Gears – CNC ground and planetary drive ready, providing strength and precision.
Input Shaft Gears – Made from 8620 alloy steel, AGMA 10 rated for heavy-duty applications.
Flange Gears – CNC-machined forged steel, designed for high-torque performance.
Axle Gears – Forged and precision-machined to meet demanding power transmission requirements.
Gear Blank Forging (Hot & Ring Forging)
We produce high-strength gear blanks through:
- Hot forging of gear blanks with improved grain structure and fatigue strength
- Ring forging for large-diameter gears, enhancing concentricity and cost-efficiency
- Pre-machining of forged blanks to allow minimal stock removal
Materials: Alloy steel (42CrMo, 20CrMnTi, 18CrNiMo7-6), stainless steel, tool steel
Gear Machining Processes
Our gear machining workflow is designed to achieve precise tooth geometry and consistent quality across production batches:
CNC Turning & Milling – Establishes accurate reference surfaces on forged blanks
Gear Hobbing – Efficient tooth profile generation for spur and helical gears
Gear Shaping – Enables internal gears and complex tooth geometries
Gear Grinding – Enhances surface finish and tooth accuracy for smooth meshing
Heat Treatment & Surface Hardening – Improves wear resistance and load capacity
Each step is monitored to ensure repeatability and compliance with customer specifications.
Gear Accuracy, Standards & Inspection
Gear machining accuracy is critical to transmission efficiency, noise control, and service life. At Weforging, gear machining processes are controlled to meet defined accuracy grades and international standards commonly specified in OEM projects.
We manufacture and machine gears in accordance with:
AGMA standards for gear accuracy, load capacity, and performance classification
DIN and ISO standards for tooth geometry, pitch, and dimensional consistency
Customer-specific drawings and technical specifications
To ensure gear quality, inspection and verification are integrated throughout production, including:
Tooth profile, lead, and pitch inspection
Concentricity and runout measurement
Coordinate measuring machine (CMM) inspection
Material and heat treatment verification
This inspection-driven approach ensures stable gear performance, predictable meshing behavior, and repeatable quality across production batches.
Gear Machining Methods: Hobbing vs Shaping vs Grinding
| Aspect | Gear Hobbing | Gear Shaping | Gear Grinding |
|---|---|---|---|
| Applicable Gear Types | Spur gears, helical gears | Internal gears, complex tooth profiles | Spur gears, helical gears, precision gears |
| Typical Application | General-purpose and medium to large batch production | Internal gears and gears where hobbing is not feasible | High-precision and heavy-duty applications |
| Accuracy Level | Medium to high accuracy | Medium accuracy | High to very high accuracy |
| Surface Finish | Good | Good | Excellent |
| Production Efficiency | High | Medium | Lower (finishing process) |
| Flexibility | Limited for internal gears | High for complex and internal gears | Focused on accuracy improvement |
| Common Use Stage | Primary tooth cutting | Primary tooth cutting | Final finishing process |
| Typical Standards | AGMA / DIN / ISO | AGMA / DIN / ISO | AGMA / DIN / ISO |
| Key Advantage | High productivity and consistent tooth geometry | Ability to machine internal and complex gears | Improved tooth accuracy, lower noise, better meshing |
By combining gear hobbing, shaping, and grinding, manufacturers can achieve the optimal balance between production efficiency, accuracy level, and long-term gear performance based on application requirements.
Equipment Overview
Our gear machining facility is equipped with:
CNC gear hobbing machines (YKD315, YKD500)
Gear shapers and profile grinding machines
Vertical and horizontal CNC lathes
Tooth measuring systems and coordinate measuring machines (CMMs)
Heat treatment furnaces and in-house quality control equipment
We support batch sizes from prototype to 10,000+ units, with full traceability and inspection records provided for each production lot.
Applications and Industries
Construction Machinery Gearboxes
Forged gears in heavy-duty gearboxes handle extreme loads and ensure long-term durability on construction sites.Transmission Gears for Trucks & Agricultural Equipment
Precision-machined gears provide efficient power transfer and reliable performance in mobile machinery.Wind Turbine Gear Rings
Large forged gear rings deliver stability and torque resistance for continuous operation in renewable energy systems.Precision Gears for Valve Actuators & Drives
High-accuracy gears ensure smooth control and performance in industrial automation and control equipment.Hydraulic Motor Gears & Pump Components
Wear-resistant gears enhance efficiency and reliability in hydraulic systems and fluid power applications.
These applications often require gears with high load capacity, long service life, and stable dimensional accuracy. Our engineering team can support custom gear machining solutions based on specific operating conditions.
Why Choose Weforging for Gear Machining?
OEM customers choose Weforging not only for gear machining capacity, but for engineering-driven manufacturing support:
Integrated forging-to-finish gear machining capability
CNC machining of hot forged and ring forged gear blanks
Small MOQ support and fast prototyping
ISO 9001 certified quality management system
Export experience across 20+ countries
Our engineering team supports DFM analysis, tolerance stack-up review, and 2D/3D drawing integration, with 100% inspection applied according to project requirements.
Start Your Gear Machining Project
Looking for a reliable supplier for precision gear machining from forged blanks?
Send us your gear drawings or technical specifications for engineering review and quotation. We provide clear process planning, realistic lead times, and stable production support for OEM programs.
