Gear Manufacturing

Gears have been used extensively for the transmission of power. They find application in almost all modern machinery. To meet the strenuous service conditions, gears should have robust construction, reliable performance, high efficiency, and long life. Also, gears should be fatigue and stress free to avoid failure which could lead to disastrous conditions. In the changing gear manufacturing landscape, choosing the most efficient and accurate machining method and gear tooling is essential. At Karkhana.io, we employ a variety of tools and gear manufacturing processes to suit your application and batch size requirements.
We produce gears for Automotive, Machinery, Agriculture and Robotics applications.

Why Karkhana.io for Gear Manufacturing?

Get high quality parts every time!

Rapid Prototyping

Supercharge your development cycle of prototype - test - repeat. Karkhana.io provides you access to quick turn around for high quality prototyping in 20+ metal alloys and 50+ industrial-grade plastics.

Low Volume Production

Do not compromise on customised features that are tailored to your modern product applications. Implement low-volume pilot or short-term production runs.

Real-Time Manufacturability Feedback

Our design for manufacturability (DFM) feedback will enable you to design and iterate quickly and efficiently. Use our Engineering team like your own to discuss and finalize a part that Karkhana.io can produce. Get parts in 1 day

Get Quality Right the First Time

Challenges with Quality and multiple reworks are quite a bummer for fast moving teams. With two stages of quality inspection and constant communication on project status, Karkhana.io ensures that you receive parts right the first time, every time.

Fair Pricing

You get in-depth insights to improve your design for manufacturing, choose the right material and get fair pricing for fabrication.

Massive manufacturing capacity

Instantly access the production capacity of over 150+ manufacturers with wide-ranging capabilities and certifications across India from your desktop.

150+

Manufacturing partners

1 .8 m +

Parts & prototypes produced

80+

Customers served

Common Gear Types

Spur gears transmit power through shafts that are parallel. The teeth of the spur gears are parallel to the shaft axis. This causes the gears to produce radial reaction loads on the shaft, but not axial loads. Spur gears tend to be noisier than helical gears because they operate with a single line of contact between teeth.

Helical gears have teeth that are oriented at an angle to the shaft, unlike spur gears which are parallel. This causes more than one tooth to be in contact during operation and helical gears are capable of carrying more load than spur gears. Due to the load sharing between teeth, this arrangement also allows helical gears to operate smoother and quieter than spur gears. Most enclosed gear drives use helical gears.

Bevel gears are most commonly used to transmit power between shafts that intersect at a 90 degree angle. They are used in applications where a right angle gear drive is required. Bevel gears are generally more costly and are not able to transmit as much torque, per size, as a parallel shaft arrangement.

Worm gears transmit power through right angles on non-intersecting shafts. Worm gears produce thrust load and are good for high shock load applications but offer very low efficiency in comparison to the other gears. Due to this low efficiency, they are often used in lower horsepower applications.

Gear Generating

Most cut gears produced in big numbers are made on machines that utilize the gear-generating method. The two primary generating processes are hobbing and shaping.
Hobbing uses a helically-fluted cutting tool called a hob. Both the hob and the workpiece rotate as the hob is fed axially across the gear blank. Hobbing is limited to producing external gear teeth on spur and helical gears
Shaping produces gears by rotating the workpiece in contact with a reciprocating cutting tool. The cutter may be pinion shaped, a multi-tooth rack-shaped cutter, or a single-point cutting tool.

Gear form-cutting

Uses formed cutting tools that have the actual shape, or profile, desired in the finished gear. The two primary form-cutting methods are broaching and milling.
Broaching is the fastest method of machining gears and is performed using a multi-tooth cutting tool called a broach. Each tooth on the broach is generally higher than the preceding tooth. As a result, the depth of cut increases with each tooth as the broaching operation progresses. Broaching is typically used to produce internal gear teeth.
Milling is a basic machining process which uses the relative motion between a rotating, multi-edge cutter and a workpiece to cut individual gear teeth. A variation of the process, called “gashing”, is used to produce large, coarse pitch gears. Gashing is used on heavy-duty milling machines and involves plunging the rotating cutter into a blank for rapid metal removal.

Our Customers Love Us

Trusted by engineers and purchasing leaders at the world’s most successful companies. Over 1 million parts delivered

“Karkhana.io brings with it not just the vendor connects and know how, but also the design and engineering skills needed to prototype and manufacture completely new parts that are complex and have tight tolerance requirements.”

Bharath Patil

Co Founder and CTO

“Karkhana.io supercharges our product development. We are always assured a timely delivery and part quality that far outbeats that of working with unorganized players. The team is highly cooperative and knowledgeable. Would recommend working with them.”

Rohan Vadgaonkar

Co Founder and CEO

“Karkhana.io is reliable supplier in terms of quality and timeline for any type of machined and Plastic components.Thank you so much for doing a great work.”

Jitendra Chaurasia

Procurement Executive

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