mitre and bevel gears
Precision Mitre and Bevel Gears for High-Torque Power Transmission
1. Product Overview
Our premium range of mitre and bevel gears is engineered for demanding industrial applications requiring precise angular power transmission. Designed to operate at 90-degree shaft angles with optimal efficiency, these gears deliver smooth, quiet performance under high torque loads. Manufactured from case-hardened alloy steel and precision-ground tooth profiles, our mitre and bevel gears provide exceptional durability and minimal backlash, making them ideal for critical drivetrains in automation, material handling, and heavy machinery.
Available in straight, spiral, and zerol configurations, each gear set is matched for perfect meshing and load distribution. Whether you require standard ratios or custom modifications, our products meet AGMA Class 10-12 quality standards for reliable, long-service operation.
2. Key Features
- High Load Capacity: Case-hardened to 58-62 HRC with ground tooth flanks for superior wear resistance and fatigue life.
- Precision Alignment: Axial and radial runout controlled within 0.02mm for vibration-free operation at speeds up to 3,000 RPM.
- Low Backlash: Standard backlash of 0.05-0.10mm for precise positioning in servo-driven applications.
- Versatile Configurations: Straight bevel for simple 1:1 ratios, spiral bevel for smooth engagement, and mitre gears for equal-speed right-angle drives.
- Corrosion Resistance: Optional black oxide, phosphate, or nickel-plating finishes for harsh environments.
- Interchangeable Design: Standardized mounting dimensions compatible with major global gearbox manufacturers.
3. Technical Specifications
| Parameter | Straight Bevel | Spiral Bevel | Mitre Gears |
|---|---|---|---|
| Module Range | 1.0 - 12.0 | 1.5 - 10.0 | 1.0 - 8.0 |
| Pressure Angle | 20° | 20° | 20° / 14.5° |
| Maximum Pitch Diameter | 300 mm | 400 mm | 250 mm |
| Hardness (Case) | 58-62 HRC | 58-62 HRC | 55-60 HRC |
| Backlash | 0.05-0.15 mm | 0.05-0.12 mm | 0.08-0.20 mm |
| Max Torque (at 1:1) | 850 Nm | 1,200 Nm | 600 Nm |
| Efficiency | 95-98% | 96-99% | 94-97% |
| Material | 20CrMnTi / 8620 | 20CrNiMo / 4320 | 45# Steel / 40Cr |
| Surface Finish | Ra 0.8 μm | Ra 0.6 μm | Ra 1.2 μm |
Custom specifications available upon request. All dimensions in metric system.
4. Application Scenarios
Our mitre and bevel gears are deployed across diverse industries where space constraints and angular power transfer are critical:
- Industrial Automation: Robotic arms, rotary indexing tables, and pick-and-place units requiring precise 90-degree motion.
- Material Handling: Conveyor drives, lift tables, and palletizers where compact right-angle gearboxes are essential.
- Agricultural Machinery: PTO shafts, mower decks, and tiller gearboxes requiring high shock-load resistance.
- Mining & Construction: Crushers, screening equipment, and auger drives operating in dusty, high-vibration environments.
- Marine Applications: Steering systems, winch drives, and propulsion auxiliary units needing corrosion-resistant gearing.
- Renewable Energy: Solar tracker drives and small wind turbine yaw mechanisms demanding reliable long-term operation.
5. Advantages
- Optimized Tooth Geometry: Finite element analysis (FEA) ensures uniform stress distribution, reducing pitting and tooth breakage risks.
- Noise Reduction: Spiral bevel designs with 35° helix angle provide progressive tooth engagement, lowering noise by 8-12 dB compared to straight bevels.
- Thermal Stability: Special heat treatment processes minimize distortion during hardening, maintaining dimensional accuracy at operating temperatures up to 150°C.
- Interchangeable Mounting: Standardized bore diameters and keyway dimensions allow direct replacement of competitor products without modification.
- Cost-Effective Production: High-volume manufacturing with CNC hobbing and grinding ensures competitive pricing without sacrificing quality.
6. Why Choose Us
- 20+ Years of Gear Manufacturing Expertise: We have supplied mitre and bevel gears to over 500 industrial clients across 40 countries.
- Certified Quality Systems: ISO 9001:2015 and IATF 16949 certified processes ensure consistent product quality and traceability.
- Engineering Support: Our team provides free application engineering, including load calculations, mounting recommendations, and custom design services.
- Rapid Prototyping: 3-5 day turnaround for sample gears using 5-axis CNC machining for quick validation.
- Global Logistics: Stock inventory in regional warehouses (USA, Germany, Singapore) enables 48-hour delivery for standard sizes.
- 100% Inspection: Every gear set undergoes dimensional verification, hardness testing, and noise/vibration analysis before shipment.
7. FAQ
Q: What is the difference between mitre gears and bevel gears?
A: Mitre gears are a specific subset of bevel gears with a 1:1 ratio and equal-sized gears, typically used for right-angle drives where input and output speeds are identical. General bevel gears can have various ratios (e.g., 2:1, 3:1) and different tooth counts on each gear.
Q: Can you supply matched sets of mitre and bevel gears?
A: Yes, all our gears are manufactured and tested as matched pairs. We recommend ordering complete sets (pinion + gear) to ensure optimal contact patterns and backlash control.
Q: What lubrication do you recommend?
A: For most applications, ISO VG 220-320 EP gear oil is suitable. For high-speed or high-temperature environments, synthetic PAO or PAG oils provide better thermal stability and extended service intervals.
Q: How do you handle custom bore sizes or keyways?
A: We offer custom machining services with typical lead times of 5-7 working days. Provide your shaft diameter, keyway dimensions (width, depth, length), and any special tolerances in your RFQ.
Q: What is the typical lead time for standard products?
A: Standard mitre and bevel gears (module 2-6, common ratios) ship within 3-5 business days from our stock. Larger modules or special materials may require 15-20 days for production.
Q: Do you provide technical documentation for CE/UKCA compliance?
A: Yes, each shipment includes material certificates, dimensional inspection reports, and a declaration of conformity for EU/UK markets upon request.
Contact our engineering team today for a free application review and quotation on your specific mitre and bevel gear requirements.