±0.005 mm Tolerance Burr-Free Wire EDM Gears and Pre-Hardened Wire EDM Gear Assemblies

Engineered for mission-critical power transmission, automated robotics, aerospace actuators, and heavy-duty drivetrain systems, this dual-ring lightweight spur gear assembly demonstrates the capability of advanced slow-feeding Wire Electrical Discharge Machining (Wire EDM) combined with 5-axis CNC turning and milling.

When conventional gear hobbing, shaping, or broaching faces geometrical constraints—such as narrow clearances between stepped gear tiers, intricate weight-reduction cutouts, or fully pre-hardened tool steels—Wire EDM delivers non-contact, burr-free precision down to ± 0.005 mm (±0.0002") with zero mechanical cutting stress.

Wire EDM bypasses tool wear and deflection limits common in standard mechanical tooth cutting methods:

• Pre-Hardened Machining Integrity: Components can be completely heat-treated (quenched, tempered, or case-hardened) before final gear wire cutting. This eliminates the post-machining warping and dimensional distortion typical of heat-treating hobbed gears.
• Lightweight Webbed Geometry: The pocketed weight-reduction spokes on the primary gear face are pre-machined via high-speed CNC milling, while the outer and inner gear rings are EDM-wire profiled, keeping rotational inertia minimal without sacrificing torsional rigidity.
• High Tooth-Pitch Consistency: Multi-pass skim cutting achieves true involute profiles with uniform flank contact, reducing tooth backlash, vibration, and gear noise in high-RPM operations.
• Complex Multi-Tier Features: Machining multiple concentric gear teeth and central splined bores on a single monolithic or rigidly indexed assembly ensures concentricity within 0.008 mm.

• Robotics & Cobot Actuators: Zero-backlash strain-wave and planetary reduction stages requiring tight involute profiles.
• Aerospace & Defense: High-strength, weight-optimized transmission gearing and control surface drive mechanisms.
• Automotive & Motorsport Racing: Custom differential spur gears, transmission input rings, and high-tensile starter gears.
• Special-Purpose Machinery: Synchronized timing gears, indexing tables, and automation drive linkages requiring custom modules.

1. Send complete 2D manufacturing drawings (PDF/DWG with designated module, pressure angle, and backlash limits) alongside 3D CAD files (STEP/IGES).
2. Specify core hardness or case depth requirements (e.g., 58–60 HRC, carburized or through-hardened).
3. First-article CMM and gear tooth profile inspection reports, material mill certificates, and surface roughness logs are verified and included with shipment.