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Help CenterLarge Gear Hobbing Machining With In-house Heat Treatment, Hardness HRC58-62, for Mining Equipment
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Henan San Kuang Machinery Technology Co., Ltd. specializes in the production of large gear hobbing machining with in-house heat treatment, achieving a hardness of HRC58-62 specifically designed for demanding mining equipment applications. Since our establishment in 2014, we have built a 10,000–30,000 m² factory and a team of 51–100 skilled professionals, ensuring every gear meets rigorous quality standards. Our integrated heat treatment process eliminates outsourcing risks, providing consistent hardness and superior wear resistance for heavy-duty mining operations.
Our large gear hobbing service is tailored for mining equipment such as excavators, crushers, ball mills, and conveyor systems. The gears are manufactured from high-quality alloy steels (e.g., 20CrMnTi, 42CrMo) and undergo a precise carburizing, quenching, and tempering cycle to achieve the specified HRC58-62 surface hardness while maintaining a tough core. This combination delivers exceptional fatigue life and resistance to impact loads, reducing downtime and maintenance costs.
Key Technical Specifications
| Parameter | Available Range |
|---|---|
| Material | Alloy steel (20CrMnTi, 42CrMo, 40Cr, etc.) |
| Hardness | HRC58-62 (surface), core HRC30-40 |
| Max Outside Diameter | Up to 2000 mm (optional, upon request) |
| Module | Up to 30 (customizable) |
| Gear Type | Spur, helical, bevel, internal, custom profiles |
| Precision Grade | DIN 6–8 (customizable up to DIN 5) |
| Heat Treatment | Carburizing, quenching, tempering (in-house) |
Product Features & Benefits
In-House Heat Treatment: Our integrated heat treatment facility ensures uniform hardness control, shorter lead times, and lower costs compared to outsourced treatment. The entire process is monitored by certified metallurgists.
High Wear Resistance: With HRC58-62 surface hardness, our gears resist abrasive wear from rocks, ores, and debris in mining environments, extending service life by 30–50% compared to standard gears.
Heavy-Duty Load Capacity: Designed for high torque and shock loads, the gears feature optimized tooth profiles and deep case hardening to prevent pitting and breakage.
Precision Hobbing: CNC hobbing machines with advanced tooling achieve tight tolerances (up to DIN 6) for smooth meshing, reduced noise, and improved power transmission efficiency.
Customizable Dimensions: We offer a wide range of diameters, modules, and tooth counts to match your equipment specifications. Custom gear profiles are also available.
Full Traceability: Each gear is marked with a unique serial number, and material certificates, heat treatment charts, and inspection reports are provided upon request.
Why Choose Our Large Gear Hobbing Service?
Our dedication to quality and reliability is backed by ISO9001, ISO14000, OHSAS18001 and other management system certifications, ensuring consistent processes and continuous improvement. With an annual export value of US$2.5–5 million and shipments to ports including Shanghai, Qingdao, and Tianjin, we serve customers across North America, South America, Europe, Africa, and Asia. Our team of 51–100 employees includes experienced engineers who can provide technical support for gear design, material selection, and heat treatment optimization.
In addition to large gear hobbing, we offer a comprehensive range of services including gear grinding, gear shaping, spline cutting, and complete machining of gearboxes. This one-stop capability reduces your supply chain complexity and ensures compatibility across all components.
We understand the critical role gears play in mining operations. Our large gear hobbing machining with in-house heat treatment delivers the durability and precision your equipment demands. Contact us today with your drawings or specifications, and we will provide a tailored solution with competitive pricing and fast turnaround.
Frequently Asked Questions (FAQ)
Q1: What is the minimum order quantity for large gear hobbing?
A: Our minimum order quantity is typically 1 piece for prototypes or small batches. For large production runs, we can offer volume discounts. Please contact us with your specific requirements.
Q2: How long does it take to produce a custom gear?
A: Lead time depends on complexity and size. Standard gears (up to 1000 mm diameter) can be delivered in 4–6 weeks, including heat treatment. Larger or more complex gears may require 8–12 weeks. We also offer expedited services for urgent orders.
Q3: Can you achieve a hardness higher than HRC62?
A: Yes, we can customize the heat treatment to achieve higher hardness up to HRC64, but this may affect core toughness. We recommend HRC58-62 for the best balance of wear resistance and impact strength for mining applications.
Q4: Do you provide material certificates and inspection reports?
A: Absolutely. We provide material test certificates (MTC), heat treatment charts, hardness test reports, and dimensional inspection reports (CMM or gear inspection machine) for every order upon request.
Q5: What types of mining equipment are your gears suitable for?
A: Our gears are widely used in excavators, bulldozers, draglines, crushers, ball mills, conveyor systems, and underground mining machinery. We can also adapt to special applications with custom design.
Q6: Can you handle gears with a diameter over 2 meters?
A: Our current capacity allows us to hob gears up to 2.5 meters in diameter. For larger sizes, we can discuss alternative manufacturing methods such as gear shaping or segmental design. Please contact us for feasibility.
Q7: How do you ensure the quality of the in-house heat treatment?
A: Our heat treatment department is equipped with controlled atmosphere furnaces, quenching tanks, and tempering ovens. We follow strict process parameters (temperature, time, cooling rate) and perform 100% hardness testing on every gear. Case depth is verified by metallographic analysis as needed.
Q8: Do you offer after-sales support or warranty?
A: Yes, we offer a standard 12-month warranty against manufacturing defects. Our technical team is available for remote support and, if necessary, on-site inspection. We also provide spare parts and maintenance recommendations.
With a proven track record of delivering thousands of large gears to mining companies worldwide, Henan San Kuang Machinery Technology Co., Ltd. is your trusted partner for durable, high-performance gear solutions. Our in-house heat treatment, combined with precision hobbing and strict quality control, ensures that every gear meets the demanding requirements of the mining industry. Contact us today to discuss your project and experience the San Kuang difference.
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