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We received a consultation from a customer regarding changes in the noise of the bevel gears within a lot, but they were unsure of the cause. At OJIC, we conducted an investigation into the cause by providing bevel gears and performing engagement tests and measurement of engagement transmission errors. As a result of the measurement tests, it was determined that there were areas with poor tooth contact. Therefore, we modified the assembly distance and carried out adjustment work on the bevel gears to achieve appropriate tooth contact and engagement transmission errors. As a result, the changes in noise of the bevel gears within the lot were eliminated. [Case Summary] ■ Issue: Changes in the noise of bevel gears within a lot, but the cause is unknown ■ Proposal: Adjust the bevel gears to achieve appropriate tooth contact and engagement transmission errors ■ Result: Changes in noise of the bevel gears within the lot were eliminated *For more details, please refer to the PDF document or feel free to contact us.

• gear
• Other contract services
• Other services

We would like to introduce a technical proposal case that achieved quality improvement and noise reduction for gears from other manufacturers that were generating noise. The customer reported that noise occurred while using gears from another company, but that company was unable to resolve the noise issue. As a result of our measurement investigation, it was determined that the cause of the noise was due to poor tooth profile error and pitch error. We proposed remanufacturing the gears with corrected tooth profile and pitch errors, and delivered them. By machining with even higher precision than the customer's requirements, we were able to improve the noise issue. 【Case Summary】 ■ Problem: Noise occurred when using gears from another manufacturer ■ Proposal: Remanufacture gears with corrected tooth profile and pitch errors ■ Result: Successfully improved noise *For more details, please refer to the PDF document or feel free to contact us.

• Contract measurement
• Contract manufacturing
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Many people may be troubled by the noise of gears (gears). The noise from gears can be caused by various factors. Depending on the cause, it may be easily resolved, or there may be cases where the cause cannot be identified. When you are concerned about gear noise, it is important to check all parts that could be the cause. Therefore, in this article, we will introduce some typical causes of noise in gears and their countermeasures. You can view the detailed information through the related links, so please take a look. *For more details, please refer to the PDF document or feel free to contact us.

• gear
• Other machine elements

This is a zero-roll bevel gear for robot joint axes. The size is Φ90, made of SCM, and it has undergone carburizing hardening as a heat treatment. Zero-roll bevel gears used in multi-joint robots require two main features: 1. compact size, and 2. lightweight. Therefore, this zero-roll bevel gear is designed with a thin-walled shape of 5mm. When processing gears with such a thin-walled shape, it becomes challenging to maintain dimensional tolerances and geometric tolerances during lathe processing, especially minimizing dimensional changes due to deformation during inner diameter grinding. Additionally, since zero-roll bevel gears for robots require long operating times, it is essential to have durable gears that minimize vibrations. High-quality gears can also suppress vibrations, leading to reduced wear of components and improved durability of the robot itself. Furthermore, by reducing the backlash of gears used in the robot's joints, we can minimize variations in robot movements and enhance the positioning accuracy of the arms. Our company also possesses measuring instruments that accurately measure the dimensions of these high-precision thin-walled gears, which is a notable feature that allows us to maintain quality control of the gears.

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This is a square spline for machine tools. The size is φ50, and the material is SCM, which has been subjected to carburizing and quenching as heat treatment. This square spline is used in the spindle that rotates the tool shaft of machine tools. In recent years, DD motors have generally been used for machine tool spindles, but gear drive is necessary for spindles that require cutting force and rotational torque. Therefore, a square spline capable of gear drive has been adopted. This product has a proven maximum rotational speed of 20,000 rpm, achieving high precision in gear grinding to reduce vibration and noise, as well as high precision in coaxiality through cylindrical grinding. Additionally, through our machining technology, we have achieved a fitting accuracy of within 5μm for the male and female spline parts, allowing for smooth sliding. At OJIC, we are capable of producing high-precision products like this one, based on the technology and know-how we have cultivated over 70 years. By achieving high-precision machining in this product, we prevent noise issues related to backlash and maintain the accuracy of the machining equipment equipped with this gear.

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This is a spur gear for machine tools. The size is φ150, the material is SCM, and it has undergone carburizing hardening as a heat treatment. This product is used in the spindle of machine tools, with a maximum rotational speed of 20,000 rpm. By utilizing the LNS (Low Noise Shift Grinding) from Reishauer, we manufacture tooth surface profiles that can handle high-speed rotation. Furthermore, by continuously processing the tooth surface with a screw-shaped grinding wheel, we achieve ultra-high precision machining with pitch accuracy of several micrometers. Typically, the verification of surface profile effects is conducted by the end users, but this can sometimes take a considerable amount of time. At Oujic, we possess the latest gear measuring machines and analysis software capable of measuring the surface profile of our products. By measuring the surface profile in the processing area, we can shorten the prototype period.

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This product is a timing gear used to synchronize the rotation of rotors in a blower. The size is φ150, made of SCM, and has undergone high-frequency hardening as a heat treatment. In this case, it is crucial to enhance the machining precision of the timing gear that transmits rotational power to maintain a consistent gap precision between the rotors. By performing high-precision machining based on years of accumulated know-how and achievements, we have achieved stabilization of the gap precision. Additionally, in this case, it was necessary to strictly manage the backlash of the gear pair to reduce gear noise during power transmission. We addressed this by understanding the amount of thermal expansion due to temperature management during the machining of the teeth and managing the tooth thickness dimensions. By managing the tooth thickness dimensions, we were able to ensure that the backlash remained consistent before delivery. We have a track record of producing timing gears up to a maximum size of φ660, so please feel free to consult us about larger gears. The gears produced using world-class machining equipment and manufacturing environments undergo final checks with the industry-standard Klingelnberg inspection machine, which we possess.

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This is a prototype helical gear for the automotive industry. The size ranges from φ15 to 350, made of SCM, and it has undergone carburizing hardening as a heat treatment. The manufacturing of the tooth surfaces for this product requires a special dedicated hob tool. Since it is a prototype, it was necessary to produce it in a short lead time, but obtaining and manufacturing the special hob tool made it impossible to meet the short lead time. Therefore, we shaped a grinding wheel suitable for the gear specifications on-site and performed the cutting process from solid material. This eliminated the need to purchase or manufacture dedicated tools, significantly shortening the delivery time. At OJIC, we can accommodate the production of all types of prototypes. Additionally, if you wish to have prototypes made in a short lead time, we can offer suggestions for reducing delivery times. Please feel free to consult us regarding gear manufacturing and prototyping.

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This is a case study of hypoid gears for automatic tool changers (ATC) used in machine tools. The size is φ400, made of SCM, and it has undergone carburizing and quenching as heat treatment. In this case, hypoid gears were adopted to compact the gearbox. While hypoid gears are similar to worm gears, they have a higher engagement ratio and better power transmission efficiency, which are notable advantages. By using hypoid gears, we were able to design a larger reduction ratio for the ATC, making it possible to achieve a single-stage reduction instead of the previous two-stage reduction. Furthermore, we provided optimal specifications for the machine's performance through strength calculations during load operation. As a result, the product's quietness and durability were improved. At OJIC, we can provide optimal proposals to solve our customers' problems, just like in this case. Please feel free to consult us regarding gears and gear-related matters.

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This is an example of a zero-roll bevel gear for a press machine. The material is SCM, and it has undergone carburizing and quenching as heat treatment. Previously, finishing was done through conventional gear cutting, which resulted in significant noise and vibration, causing considerable trouble for our customers. However, due to the large size of the product, the depth of heat treatment was also deep, and the weight increased, leading to distortion from heat treatment, making it difficult to maintain the ideal tooth contact position, size, and shape. In response, we proposed a gear grinding specification that can accommodate the gear grinding of large modules, such as module 12 zero-roll bevel gears. As a result, for small lot products, there was no need to purchase expensive dedicated tools, and cost reduction was achieved by performing gear cutting with grinding wheels. By achieving cost reduction and improving product quality, this case has resulted in high customer satisfaction. Our company can provide optimal proposals for cost reduction and quality improvement, similar to this case. If you have any inquiries about gears, please feel free to consult with OJIC.

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This is a case study of the production of helical gears used in labor-saving machines and conveying devices. The material is iron, and it has undergone carburizing and quenching as heat treatment. Since these products are used in labor-saving machines and conveying devices, we processed them while minimizing distortion to avoid noise and weight issues. Additionally, based on the correction amounts obtained from analyses conducted with our inspection equipment, we applied 3D correction processing to the tooth surfaces. Furthermore, considering driving loads and assembly errors, we added a unique design to optimize the tooth contact. As a result, we achieved gear production that matched the customer's requirements. At our company, we can produce gears that best meet the requests we receive from customers, just like in this case. We engage in technical consultations and pursue the optimal gears together with our customers. For anything related to gears, please feel free to consult with OJIC.

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This is a hypoid gear used in automotive transmissions and axles. The material is iron, and it has undergone carburizing and quenching as heat treatment. This case was a request for a development product in the prototype stage. Our company specializes in the production of small lots, including development products from the prototype stage and special gears for automotive racing. We can accommodate production quantities from single items to 100 sets. Additionally, after prototyping, we conduct analysis and measurement using the KIMoS gear grinding machine from Klingelnberg, and we can consistently perform engagement transmission error measurement using T60. Furthermore, through a closed-loop system, we can deliver gears that meet the design specifications, thereby achieving a reduction in development time (we also possess conversion technology to Klingelnberg equipment for summary sheets produced by other companies like Gleason). If you have any concerns regarding development products or special gears from the prototype stage, please feel free to consult with OJIC.

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This is a gear for a mechanical reducer used in elevators. It is classified as a worm gear, and since it is a component used in elevators, the machining precision of the worm gear directly affects the ride comfort during elevator ascents and descents. Additionally, due to the potential risk to human life in case of defects, it requires a machining precision that is much higher than that of typical industrial reducers. At OJIC, we have established a design for tooth engagement that minimizes transmission errors and a quality control system based on the accumulated experience with machine tools. We also adopt large modules that can withstand the weight of the elevator itself. The worm wheel is subject to polygonal errors on the machined surface due to intermittent cutting finishes on the hob machine, so we have utilized advanced machining techniques to improve the surface profile. We have received very positive feedback from our customers, and as a result of this relationship, we have begun manufacturing products that were previously produced in-house by the manufacturers. Similarly, some companies are considering switching to outsourcing due to challenges such as aging in-house equipment and difficulties in securing skilled personnel for gear machining.

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This is an example of a spiral bevel gear used in auxiliary equipment such as generators for aircraft. The size, position, and shape of the contact line, which is the tooth engagement between the driving gear and the driven gear, required high precision in the reproduction of the master gear. Therefore, the master gear was measured in three dimensions with an accuracy of 0.001 mm, and the machine settings for processing were created. In such cases, technologies for measuring tooth surfaces and for processing are necessary, and without sufficient experience in using the equipment, quality management capabilities, and facility capabilities, it is a highly challenging request that cannot yield satisfactory results. Additionally, this gear is a high-speed rotating component, and it was a case where details such as surface roughness and the root radius were meticulously checked to maintain strength. At Oujic, we have been manufacturing spiral bevel gears for many years, and we excel in such requests. We possess analysis technology for the tooth parts and the associated equipment, and we have the technical capability to respond effectively to the requests from our customers. In this case, we reproduced the machine settings provided by the customer and further aligned it with the master gear.

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This is a curvic coupling used in horizontal machining center tables and turret tool holders of lathes. More specifically, it is a product example that is in high demand for index tables. The positioning of the rotation direction and the runout of the end face of the index table are determined by this curvic coupling, making it a component that directly contributes to the machining quality of horizontal machining centers. For such curvic couplings, we provide custom-made solutions tailored to the shapes designed by our customers. Considering that there may be cases where replacement is needed during maintenance, we measure the master coupling owned by the customer, reproduce the same tooth profile, and manufacture it. We first borrow the customer's master coupling and conduct 3D measurements. From there, we create machine settings, perform reproduction and trial machining, and proceed with production. We have also achieved high precision in pitch accuracy while ensuring proper engagement with the master coupling.

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This is a case of helical gears for drive wheels in an automatic transport device. The gears themselves are lightweight, yet they are components required to move heavy objects. In such cases, quiet operation is essential, but the thin-walled blank shape is prone to distortion, making process design and distortion management to maintain machining accuracy very challenging. At OJIC, we are equipped with advanced process design and distortion control based on our extensive experience and achievements, as well as state-of-the-art machining and inspection equipment. Additionally, for thin-walled products, the method of securing the product during each manufacturing process is crucial, so we provide support starting from the design of fixtures that ensure stable positioning during machining. As a result, despite the thin-walled and distortion-prone shape, we were able to maintain the correct tooth profile and pitch accuracy, receiving positive feedback from our customers.

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This is a Karvik coupling used for fastening turbines. It is a heat-resistant alloy that is difficult to process, and due to the turbine's unique irregular shape, chucking was challenging. Additionally, since the turbine operates at a rotational speed of 70,000 to 80,000 RPM, the weight balance between the parts connected via the Karvik coupling is crucial, and the machining was very focused on the pitch accuracy of the teeth. Furthermore, due to the centrifugal force from high speeds, the material deforms, resulting in a special tooth contact for the coupling. In terms of coupling strength, achieving high precision in the machining of the coupling, such as the radius at the tooth base and the runout after coupling connection, was quite difficult. In this case, there were no issues such as tooth surface burning with the difficult-to-machine material during the coupling processing, and we were able to maintain machining accuracy, allowing for smooth delivery without quality control problems. Moreover, we have many examples of Karvik couplings at our company, and we can handle the machining of Karvik couplings located at the edges of impellers and discs. Additionally, we can select optimal tools and set processing conditions for heat-resistant alloys such as titanium and Inconel, so if you have any questions regarding gears, please feel free to contact us from the design stage.

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This is a case study of a high ratio hypoid gear used in robot joints. This example features a gear ratio of 1:30, designed with optimal tooth contact in mind, even under load conditions. The design method for this gear has not yet been established by the manufacturer of the design software. While this was a very challenging project, we combined the expertise of our skilled engineers with the latest software to create the design. We also implemented various adjustments, including closed-loop systems with machining and measurement equipment to reproduce the completed design, ultimately achieving realization. As a result, we were able to reproduce the tooth contact as designed, leading to a satisfactory outcome for our customer. High ratio hypoids are characterized by a tendency to generate heat due to high sliding speeds on the tooth surfaces. Since we understand these operating conditions, we were able to consider such characteristics during the design phase and process the gear accordingly, preventing potential issues before they arose. This level of technical capability is made possible by our proud know-how. If you have any concerns regarding gear processing or manufacturing, please feel free to consult with OJIC.

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This is a spur gear used in precision reducers for robots. The size is φ100, the material is SCM, and it has undergone carburizing and quenching as heat treatment. This case was a request for a prototype. As mentioned earlier, since it is a gear used in precision reducers, the requirements were 1. lightweight, 2. quiet operation, and 3. low vibration. Additionally, the customer desired a high-precision tooth profile correction of ±1 micron. To meet these requirements, technology and know-how to control machine vibrations and temperatures are necessary. Therefore, Oujic performed ultra-high-precision processing using a uniquely tuned gear grinding machine. The high-precision processing, which is difficult for other companies with the same machinery, was supplemented by the skills of our operators. As a result, we were able to manufacture gears that met all of the customer's requirements within a short delivery time. Since this was a project that other companies could not handle, the customer was very satisfied with our technical capabilities. As in this case, our company has many skilled operators with high technical capabilities, making it possible to produce high-precision gears. Please feel free to consult us regarding anything related to gears.

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This is a product example of gears used as a reduction gear for electric vehicles' e-axles. Specifically, these are helical gears used in transmissions. The gears rotate at high speeds, such as 15,000 rpm, requiring high quality. Due to the need for precise evaluation of the tooth surface shape, we conducted an assessment of the tooth surface flatness using the GDA software we possess. We feel that this evaluation could only be performed by our company, which specializes in gear manufacturing, and it was a measurement that would be difficult for other companies to achieve. As a result of the measurements taken with the GDA, it was found that changing the processing conditions could yield higher manufacturing precision. Additionally, we have measuring equipment capable of maintaining and managing tooth profile corrections within a few micrometers, allowing us to manufacture while appropriately maintaining and managing the process. Furthermore, we proposed that by polishing the tooth surface to a mirror finish, we could reduce tooth surface damage, vibration, and noise. In fact, by focusing the evaluation on tooth surface characteristics that could not be assessed with previous gear measuring machines, we have been able to evaluate the effectiveness of polishing grinding and low-noise shifts.

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This is a case study of grinding processing for trochoidal tooth profiles used in industrial machinery. The tooth profile is required for precision indexing parts where backlash is a concern, and it is utilized in various fields, including robotics, aviation, and motors, in addition to industrial machinery. Since it is a special tooth profile, the request required specific demands for processing equipment, measuring instruments, and evaluation methods. The shape was different from the tooth profile designed by each machine manufacturer, so the customer provided the coordinates of the tooth profile shape, and we proceeded with grinding and evaluation. At our company, we utilized the latest gear grinding machines, such as the VIPER500W and P100L, to process gears of arbitrary shapes. When measuring arbitrary shapes, it is necessary to make contact with the measuring probe perpendicular to the coordinate points on the tooth surface. Therefore, it is essential to understand the required shape and ensure that the measuring equipment can maintain the appropriate measurement position. As a result, the evaluation by the customer was satisfactory, and we received high praise even for arbitrary tooth profiles that are not specified in standards.

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This is an example of a spur gear used in the drive unit of a drone. It was a case where we were commissioned to manufacture gears as a prototype development product. Since the gears are used in drones, they required a small module and a lightweight blank shape. Additionally, due to the active research and development in the industry, there was a request for short lead times for processing at the time of the order. Our company has a specialized team skilled in thin-walled processing, and we carried out the blank processing in that department. Since these are aircraft-related parts, we requested a cooperating company capable of special handling for heat treatment. Furthermore, due to the complexity of the blank shape, process design was challenging, and we took measures to minimize deformation of the blank shape by setting excess material. As a result, we were able to achieve the thin-walled shape requested at the time of the order, and we managed the special processes such as heat treatment without any issues. Additionally, while chamfering is necessary at each corner for stress dispersion, manual chamfering was required for the tooth parts. To suppress variations in quality from such manual work, we continuously conducted shape measurements and quality checks during processing.

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This is a product case of spur gears used as the drive component for air conditioning equipment. Specifically, it was a part of air conditioning equipment used for commercial purposes, such as in offices and restaurants. Since it was equipment used by various companies, minimizing noise was a significant focus in this case. To reduce noise, the machining accuracy of the gears and the fitting accuracy of the shaft were extremely important. By repeatedly discussing the process design, we were able to manufacture the product in the shortest possible time. We performed tooth shape corrections suitable for the operating conditions requested by the customer and designed it to accommodate changes in operating posture. We made various proposals, including changes in heat treatment and material, which ultimately led to a significant improvement in quality management. In fact, we received feedback that noise and vibration were reduced compared to previous suppliers, resulting in long-term adoption of our product.

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This is a product case of a worm gear used for indexing tables in machine tools. Due to its application directly affecting the precision of the processed workpiece, this project required extremely stringent transmission errors and gear strength. It is important to achieve the appropriate machining accuracy for the product, not only in terms of gear precision but also in the dimensions and geometric tolerances of the machining reference surfaces and fitting parts. To address such challenging requests, our company utilizes hob machines equipped with custom-made ultra-high precision worms from manufacturers and gear transmission error measurement devices to achieve high-precision machining and quality assurance. Additionally, for the worm wheel, we have improved strength by using special materials (special high-strength brass) provided by our partner companies, surpassing the strength of commercially available copper alloys. The tooth contact, which is directly related to gear strength, is adjusted and processed by skilled craftsmen in the machining field to suit the specific needs of the customer. Based on past achievements, we extract and understand the critical parts from the provided drawings for assembly and machining, and we grasp the key points for inspection. We are capable of producing high-precision worm gears for tables like the case presented, so please consult with OJIC.

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This is a product example of large bevel gears used in industrial machinery. Specifically, these bevel gears were used in gearboxes for ships, railway vehicles, and large milling machines. There was a demand for spiral bevel gears with a diameter of up to Φ800 to be machined, and by using a gear cutting machine compatible with dry cutting and the latest gear grinding machine capable of grinding up to Φ800, we were able to manufacture large bevel gears at low cost and with high precision. We received feedback from customers that being able to procure gears domestically, which they had previously purchased from overseas, led to improvements in QCD (Quality, Cost, Delivery), making this a rewarding case for our company. At OJIC, we manufacture a variety of gears, from large gears like the ones in this case to small gears such as Φ10. If you want to improve the precision of your gears, reduce manufacturing costs, or have any other concerns related to gears, please consult our company, which specializes in gear manufacturing.

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This is a small module bevel gear used in robot joints. The material is SCM, and it has been subjected to carburizing heat treatment. The positional accuracy of a robot arm is greatly influenced by the quality of the gears. In conventional products, the machining accuracy of the gears was poor, leading to unstable backlash. The customer aimed to significantly reduce backlash by performing grinding on the tooth surfaces, thereby improving positional accuracy and reducing damage to the tooth surfaces. They consulted various companies but could not find a supplier capable of grinding the tooth surfaces of these small-pitch bevel gears, which left the customer very troubled. Thus, they reached out to our company, and this became a case we handled. We reviewed the tooth surface design and selected the optimal tools. Furthermore, we purchased a special processing machine capable of high-speed rotation from overseas, creating an environment where prototypes could be produced. As a result, we successfully manufactured small-pitch bevel gears that matched the customer's requirements. Our company is committed to exploring various methods to address challenging projects that other companies may decline, just like in this case. If you have any issues related to gears, please feel free to consult with OJIC.

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This is a helical gear used in turbo refrigerators. The material is SCM, the shaft length is 1000mm, and it has undergone carburizing and quenching as heat treatment. Since it is a gear used in high-speed rotating parts, it is necessary to minimize the deflection of the long pinion shaft. Additionally, the balance of the gear is also a very important point, requiring high-precision geometric tolerances such as roundness and perpendicularity. We have designed the process considering distortion, and through our latest equipment and processing technology, we have achieved high-precision tooth profile correction and surface characteristics. Furthermore, we have also realized cost reduction by using different materials for the shaft and gear, as well as high precision through shrink fitting. As a result, even with high-speed rotation, it has become possible to manufacture gears with low vibration and noise. Our company specializes in the production of highly quiet gears like the one in this case. Please feel free to consult us regarding any gear-related matters.

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This is a product example of drive gears (spur gears) used in aircraft AGBs. Our company also manufactures gears for power transmission in transport vehicles such as airplanes and drones, and this particular request had high requirements. In terms of quality control, there are high precision demands unique to aircraft, including issues like tooth surface burning, surface roughness, root radius, and tooth profile correction. We maintain thorough management from processing equipment to inspection devices, including specially calibrated gear measuring machines and surface roughness measuring instruments. Additionally, we carry out work in accordance with customer requirements and JIS standards, including quality records, visual inspection capabilities, and handling of materials. Furthermore, since the management system for aircraft machined parts is also scrutinized, we have obtained JIS Q 9100 certification. By establishing such a rigorous management system, we are confident that we can perform grinding processes that meet the quality criteria requested by our customers. If you are facing issues with high-quality gears, tooth surface accuracy, or machining precision, please contact OJIC, which has a wealth of manufacturing experience.

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This is a bevel gear used for power transmission in electric bicycles. Initially, we received a request to create a prototype, with mass production also in consideration. Since it was a component for a bicycle, it needed to be lightweight, and there were size limitations for the gear box as well. Additionally, because it involved a hybrid drive between the motor and pedaling power, selecting the specifications was a very challenging case. The size was a gear with a diameter of Φ50 to 200 and a module of 2.5. At our company, we first used analysis software to consider the specifications. We then proposed specifications that would fit within the size constraints of the gear box. As a result, we are currently engaged in activities toward actual prototype development based on the specifications proposed by OJIC.

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This is a helical gear used in the new transmission unit of a tractor. The material is SCM, and it has undergone carburizing and quenching as heat treatment. In processing this helical gear, the burning of the tooth surface was one of the challenges. By repeatedly conducting prototype machining at our company, we identified the optimal processing conditions suitable for the gear specifications. As a result, we were able to eliminate the burning of the tooth surface and achieve the production of products as per our customer's requirements. Our company is capable of manufacturing gears that meet the specific requests from our customers, as demonstrated in this case. We engage in technical consultations to jointly pursue the most suitable gears for our customers. For any inquiries related to gears, please feel free to consult with OJIC.

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This is a spur gear used in drive equipment within a steel mill. The material is SCM, and it has undergone carburizing and quenching as heat treatment. Since it is used in a steel mill, high-quality management is required, particularly in materials, heat treatment, dimensional measurement, and ultrasonic testing. Thanks to our long-established high-quality management system, we have received high praise for our quality, with feedback indicating that our products have a longer lifespan and require less frequent replacement than usual. At our company, we can manufacture gears that are optimal for the requests received from our customers, as in this case. We conduct technical consultations and pursue the best gears together with our customers. For any inquiries regarding gears, please feel free to consult with OJIC.

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This is a variable speed gear for the spindle of machine tools. The material is SCM, and it has undergone carburizing and quenching as heat treatment. We developed an original appropriate 3D chamfer shape to address the customer's issue of not being able to perform smooth gear changes during shifting. As a result of prototyping and verification, we eliminated damage to the chamfer contact area and the occurrence of burrs on the tooth surface, achieving smooth gear changes. Our company is capable of manufacturing gears that meet the specific requests from customers, as in this case. We conduct technical consultations and pursue the optimal gear together with our customers. For any inquiries regarding gears, please feel free to consult with OJIC.

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This is a hypoid gear used as a drive gear for a rotary table. As a hypoid indexing device with a high reduction ratio, the challenge was whether it could adapt to the desired reduction ratio and the size of the gearbox. By using bevel design software, we repeatedly conducted specification design and strength calculations, successfully achieving the desired reduction ratio and strength within a satisfactory size. We were able to fit it more compactly than initially planned, and it achieved higher speeds more efficiently than a worm gear type. There were also benefits such as increased durability compared to worm gears and reduced maintenance.

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This is a worm gear used in the tables of machine tools. We received an inquiry from a customer regarding a competitor's worm gear they were using, which had poor tooth contact and needed improvement. By using our tooth contact design software TCA (Tooth Contact Analysis), along with the latest machining equipment and engagement inspections, we can reproduce the intended tooth contact as designed. By adopting our worm gear, the tooth contact has improved, leading to a reduction in assembly man-hours and an increase in durability.

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We improved the bevel gear used in the turret of a machine tool lathe. The challenge was to eliminate the vibration and noise issues of the bevel when operating at high speeds. We confirmed that the vibration was caused by backlash at the joint due to the spline and bevel being manufactured separately. We proposed a manufacturing process that could create a unified structure for our customers. By integrating the shaft and bevel, we reduced vibration, which also contributed to noise reduction in the bevel teeth. Assembly was simplified, leading to a reduction in labor costs as well.

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The customer has consulted us regarding the coupling they are using in a indexing mechanism for industrial machinery, stating that they are not achieving the desired precision after assembly. At that time, they were using a standard cubic coupling from another company along with other components, but they were having difficulty achieving the necessary assembly precision with those components, leading to issues with rigidity. Therefore, we proposed the integration of the cubic coupling with the other components, made design changes, and successfully achieved the integration. By making it a single unit, we were able to improve rigidity and reduce assembly labor.

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Our company is capable of producing masters. The customer requested the production of a master for inspection, as they are only managing the current goods with their own manufactured couplings. We received the actual product and, based on our latest inspection equipment and years of accumulated data, investigated the tooth profile shape of the curvic coupling and created processing data. We also produced an inspection master curvic coupling using the newly prepared processing data. As a result, the customer is now able to conduct inspections and pass/fail judgments using master management.

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We received a request from a customer to produce a standard Karvic coupling that has been discontinued by another company. After receiving information about the product that the customer was turned down for, we designed and manufactured a product similar to the desired standard item. As a result, we are now able to respond similarly to requests for the production of standard Karvic couplings from other customers as well.

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Due to deformation of the gear case during operation, stable meshing could not be ensured, resulting in tooth surface damage. It was determined that the cause of the gear case deformation was the thrust force generated by the spiral bevel gears. Therefore, we proposed to the customer to switch from spiral bevel gears to zerol bevel gears. As a result, the reduction in thrust force helped suppress the deformation of the gear case, allowing us to maintain the correct assembly distance. Consequently, the meshing became stable, and the damage was improved.

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When we received a manufacturing consultation from the customer, the issue at hand was that while we were currently addressing it with straight bevel gears, there was a lack of tooth surface strength in the product. To solve this problem, our company proposed improving gear precision and increasing the design flexibility of the tooth surfaces through gear grinding. We implemented a design that could enhance tooth surface precision and improve surface pressure strength using analysis software, and we proposed a zero-roll bevel gear grinding solution. As a result, we were able to increase strength compared to conventional products, confirming that it could withstand greater transmission power and larger loads while maintaining the same size, allowing us to proceed to practical application.

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We received an inquiry from a customer regarding gears used in the main spindle of machine tools, expressing a desire to reduce noise. To address this, our company calculated the optimal meshing ratio for noise reduction and proposed gears with less noise and vibration. The customer adopted our proposal, and upon actual operation, we were able to reduce noise and vibration compared to before. In addition to reducing noise and vibration, we also achieved improved stability during high-speed rotation.

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We received an inquiry from our customer regarding the stable quality of gears for railway vehicles and cost reduction in procurement. Our company has achieved low prices by handling all processing in-house, except for the heat treatment process. Additionally, we have established a high-level quality management system, a temperature and humidity-controlled factory managed 24/7, and state-of-the-art processing and inspection equipment to ensure stability and high quality.

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The spur gears used in industrial machinery were not compatible with the customer's usage conditions and the strength of the product, resulting in severe damage to the spur gears being used. The customer requested the production of similar gears for replacement, but we proposed a design change to a helical gear specification with increased tooth surface strength compared to the current situation. The customer adopted the change to the helical gear specification that could withstand the operating conditions. As a result of the specification change, the instances of damage were significantly improved.

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The customer was using a rack gear with straight teeth but requested a solution to eliminate the noise generated during operation. Our company calculated the engagement ratio and proposed optimal specifications, as well as a change from spur gear to helical gear. As a result, we were able to achieve not only noise reduction but also stable indexing accuracy.

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This is a gear for table rotation of a scientific analysis device. Due to the thin-walled and easily distorted shape of the product, the difficulty of production was high, and there were no manufacturers capable of producing it, leading to an inquiry to our company. By utilizing the know-how we have accumulated in the manufacturing of small-shaped gears, we implemented changes to lightweight jigs, managed tightening torque, and optimized hob coating, achieving stable processing including the spline section. Under the condition of finishing with gear cutting, we were able to significantly improve to JIS Class 1 standards in terms of noise and vibration. The noise issue often arises from shape changes due to distortion, but by producing stable products, we were able to meet the specified noise levels.

• gear