Comprehensive Gear Cutting Solutions
From design to delivery and lifecycle support - we provide complete gear cutting tool solutions
Custom Gear Shaving Cutters
Our specialty lies in designing and manufacturing custom gear shaving cutters tailored to your specific production requirements. We engineer cutters for automotive transmissions, industrial gearboxes, and power transmission systems.
Technical Capabilities:
- Module Range: 0.5 to 10 (metric) | DP 2 to 48 (imperial)
- Pressure Angles: 14.5°, 20°, 22.5°, 25°, and custom angles
- Helix Angles: Spur gears to 45° helical configurations
- Face Width: Up to 200mm for wide face gear applications
- Material Options: HSS, PM-HSS, Carbide, with optional coatings (TiN, TiAlN, TiCN)
- Accuracy Grade: DIN 3 to DIN 6 as per application requirements
Reverse Engineering Services
When original tool drawings are unavailable or obsolete, our reverse engineering services recreate precise tool designs from physical gear samples. We use advanced metrology equipment to capture exact geometries.
Our Process:
Sample Inspection
Comprehensive inspection of gear sample using CMM and gear measuring equipment to capture critical parameters.
Data Analysis
Analysis of profile, lead, pitch, and involute data to determine tooth geometry and manufacturing parameters.
3D Modeling
Creation of accurate 3D CAD models and manufacturing drawings with complete GD&T specifications.
Tool Design
Design of gear shaving cutter optimized for the captured geometry, including clearances and cutting parameters.
Precision Manufacturing Services
State-of-the-art equipment delivering consistent quality
CNC Machining
Equipment: 4-axis and 5-axis CNC machining centers
Rough and finish machining of gear cutter bodies, including keyways, mounting features, and complex profiles. Tolerances down to ±0.005mm achievable.
Precision Grinding
Equipment: CNC cylindrical and surface grinders
Final grinding operations for achieving micro-level surface finish (Ra 0.2 to 0.8μm) and precise tooth profiles. Critical for tool performance and life.
Heat Treatment
Process: Controlled atmosphere hardening and tempering
In-house heat treatment facility ensures proper hardness (60-65 HRC) and microstructure. Temperature monitoring and documentation for traceability.
Coating Services
Options: TiN, TiAlN, TiCN, AlCrN coatings
PVD coating services through certified partners enhance wear resistance, reduce friction, and extend tool life by 2-4 times in demanding applications.
Quality Inspection
Equipment: CMM, profile projectors, gear testers
100% inspection of critical dimensions and parameters. Complete inspection reports with measured data provided with every delivery.
Packaging & Dispatch
Protection: VCI paper, wooden boxes, foam packaging
Professional packaging with rust prevention treatment. Safe delivery through trusted logistics partners with insurance coverage and tracking.
Tool Refurbishment & Regrinding
Extend the life of your gear cutting tools with our professional refurbishment services. Our regrinding programs can restore tools to near-original performance at a fraction of replacement cost.
Refurbishment Services Include:
- Comprehensive tool condition assessment and measurement report
- Precision regrinding of cutting edges using CNC grinding equipment
- Re-hardening services if required after extensive wear
- Re-coating with TiN, TiAlN or other coatings for enhanced performance
- Complete dimensional verification and certification before return
- Typical turnaround time: 7-10 working days
- Cost savings: 40-60% compared to new tool purchase
- Multiple regrind cycles possible depending on original tool design
Technical Support & Training
Comprehensive support ensuring optimal tool performance
Onsite Tool Setup
Our application engineers visit your facility to assist with initial tool setup, machine configuration, and first article inspection. We ensure proper tool mounting, alignment, and cutting parameters for optimal performance.
Duration: 1-2 days
Included: Setup assistance, parameter optimization, training
Operator Training
Comprehensive training programs for machine operators and production supervisors covering tool handling, setup procedures, troubleshooting, and maintenance best practices.
Format: Hands-on practical training
Documentation: Operating manuals and guidelines provided
Process Optimization
Analysis of your gear shaving process to optimize cycle time, surface finish, and tool life. We review cutting speeds, feeds, coolant selection, and machine settings to improve productivity.
Benefit: 10-30% productivity improvement
Methods: Data analysis, trial cuts, parameter tuning
Troubleshooting Support
Rapid response technical support for production issues, tool performance problems, or quality concerns. Remote consultation via phone/video or onsite visit as required.
Availability: Business hours support
Response: Within 24 hours for critical issues
Service Deliverables & Lead Times
Clear expectations on outputs and timelines
| Service | Key Deliverables | Documentation | Lead Time |
|---|---|---|---|
| Custom Gear Shaving Cutters | Finished tool ready for production use | Tool drawing, material certificate, inspection report, operating guidelines | 4-6 weeks |
| Reverse Engineering | 3D CAD model, 2D manufacturing drawings | CMM inspection report, gear measurement chart, recommended cutter specifications | 2-3 weeks |
| Tool Manufacturing | Precision machined and ground tool | Dimensional inspection report, hardness test certificate, coating certificate (if applicable) | 3-5 weeks |
| Tool Refurbishment | Reground and recertified tool | Pre-regrind condition report, post-regrind inspection report, coating certificate | 7-10 days |
| Onsite Technical Support | Tool setup, process optimization | Setup parameters sheet, operator training checklist, service completion report | As scheduled |
| Consultation & Design | Feasibility study, tool recommendations | Technical proposal, cost estimates, timeline projections | 3-5 days |
Industries We Serve
Our gear cutting tools serve diverse manufacturing sectors with varying requirements for precision, durability, and performance.
Automotive Industry
Transmission gears, differential gears, starter motor gears, camshaft gears for cars, trucks, and two-wheelers.
Industrial Equipment
Gears for machine tools, conveyors, material handling equipment, and manufacturing machinery.
Agricultural Machinery
Tractor gears, harvester components, and other agricultural equipment requiring durable gearing.
Power Transmission
Gearbox components, speed reducers, and power transmission systems for various applications.
Quality Assurance Process
ISO 9001:2015 certified quality management system
Incoming Material Inspection
All raw materials undergo incoming inspection to verify material grade, dimensions, and quality. Material certificates from suppliers are verified and maintained for traceability.
In-Process Quality Checks
Critical dimensions are verified at various stages of manufacturing using calibrated measuring instruments. First piece inspection and periodic sampling ensure process control.
Final Inspection & Testing
100% inspection of finished tools using CMM, profile projectors, and gear measuring equipment. Complete inspection reports documenting all critical parameters.
Pricing & Payment Terms
Competitive pricing with flexible terms for long-term clients
Pricing Structure
Our pricing is based on several factors:
- Tool complexity (module, pressure angle, helix angle, face width)
- Material specification (HSS, PM-HSS, Carbide)
- Coating requirements (TiN, TiAlN, TiCN, etc.)
- Accuracy grade and tolerance requirements
- Order quantity and repeat order discounts
- Delivery timeline (standard vs. expedited)
Request a detailed quotation based on your specific requirements.
Payment Terms
For New Clients:
- 50% advance with purchase order
- 50% balance before dispatch
- Payment via bank transfer, RTGS, NEFT, or cheque
For Established Clients:
- Credit terms available (15-30 days)
- Annual contracts with volume discounts
- Consignment stocking options for high-volume users
Need a Custom Gear Cutting Solution?
Share your gear specifications, drawings, or samples with our engineering team. We'll provide detailed technical recommendations and competitive quotations within 48 hours.
Request a Quote