A case study of precision gear machining aimed at a clearance of 2μm. We pursue fine tooth shapes through multiple cuts, temperature management, and condition adjustments at the root of the teeth.
At Hanshin Seiko, we accept consultations for precision gears, fine tooth profiles, and complex contour shapes processed by wire cut electrical discharge machining. The case presented involves the processing of gear shapes with a target clearance of 2μm (0.002mm). We approached this considering the finish of the tooth surface, corner radii at the root, temperature variations, and wire vibrations. After rough machining, we performed multiple finishing cuts, gradually adjusting the machining cost and discharge energy. We aimed to reduce temperature differences through temperature management of the machining fluid and pre-soaking of the workpiece, while adjusting the movement speed and discharge conditions at the root. Please consult us for parts requiring narrow clearances or tooth profiles with small corner radii. Along with your drawings, please provide material, plate thickness, required tolerances, specified clearance locations, quantity, and desired delivery date. *Note: 2μm is the target clearance for this case and does not indicate achieved measured values or a uniform guaranteed accuracy.
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basic information
【Processing Conditions for the Case Study】 Processing Target: Precision parts with fine tooth shapes Processing Method: Wire cut electrical discharge machining underwater Target Clearance: 2μm (0.002mm) Finishing Method: Multiple cuts after rough machining Consideration for Temperature: Temperature management of the processing fluid, immersion of the workpiece in water for over 1 hour before processing Consideration for Shape: Adjustment of movement speed and discharge conditions at the root of the teeth Post-Processing: Ultrasonic cleaning and anti-rust treatment *The above describes the process and target conditions for this case study. A clearance of 2μm does not mean a dimensional tolerance of ±0.002mm. The applicable precision will be provided after confirming the drawings, materials, and shapes.
Price information
This is an individual estimate for each drawing. We will confirm the material, plate thickness, tooth shape, corner R of the tooth root, required tolerances, target clearance, finishing conditions, and quantity to provide the estimate.
Delivery Time
※We will confirm the drawings, required precision, finishing processes, quantities, and equipment operating status, and provide individual guidance. Please consult us with your desired delivery date.
Applications/Examples of results
【Processing Examples】 Wire cut electrical discharge machining that pursues shape accuracy of the tooth surface and root with a target clearance of 2μm. This is an example that combines multiple cuts, temperature management, processing fluid pressure, and corner condition adjustments. 【Processing Services Available for Consultation】 - Precision gears with fine tooth profiles - Parts requiring narrow clearances - Shapes with small corner radii at the root - Parts where the finish and dimensional accuracy of the tooth surface are important - Precision metal parts with complex contours *This is a contract processing service based on drawings, not the sale of standard gears.*
Company information
Hansei Seiko Co., Ltd. is a precision metal processing company founded in 1948, based in Kobe City, Hyogo Prefecture. We offer integrated processing services centered around wire cut electrical discharge machining, shape electrical discharge machining, and fine hole electrical discharge machining, as well as machining, polishing, finishing, and measurement. We welcome inquiries for precision parts, mold components, jigs, test pieces, and more, whether for single items, prototypes, or small lots. In addition to processing hardened steel, carbide, and stainless steel, we also handle contour machining of thick parts, key grooves, fine slits, and complex shapes. We confirm material, shape, required precision, and application, and consider processing conditions and processes. This reduces the burden of arranging multiple processing locations and supports part manufacturing. Based on the principle of "making according to the drawings," we conduct inspections and measurements in-house to confirm the finish before shipping. Based in Kobe and Hyogo, we accept processing inquiries and quotation requests from across the country. If you have parts you are struggling to process or drawings for which you would like to consider methods and processes, please feel free to consult with us. https://www.hansei.co.jp/
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