High Precision Forged Gear for Wind Turbine Main Gearbox Drive System Components
Our high-precision forged gears are engineered specifically for wind turbine main gearbox drive systems, where reliability, torque stability, and long-term durability are crucial. Manufactured from premium alloy steels and processed through controlled forging, heat treatment, and precision machining, these gears deliver exceptional mechanical strength and outstanding load-carrying capability under continuous variable-speed operation.
Key Features
-
High Strength & Fatigue Resistance: Forged with a high forging ratio to ensure uniform grain flow, improved toughness, and superior fatigue life in high-load wind turbine environments.
-
Precision Machined Gear Profiles: CNC hobbing, shaping, and grinding guarantee tight tolerances and low noise levels, supporting efficient gearbox performance.
-
Optimized Heat Treatment: Carburizing, quenching, and tempering processes enhance surface hardness while maintaining a tough, shock-resistant core.
-
Enhanced Reliability in Harsh Conditions: Designed to withstand long-term exposure to high torque, vibration, and fluctuating wind loads.
Applications
-
Main Gearbox High-Torque Drive Components in onshore and offshore wind turbines
-
Speed-Increasing and Power-Transmission Modules across multi-stage gearbox assemblies
-
High-load rotating systems used in wind energy equipment requiring durable and precision-forged gearing
| Item |
Details |
| Product Name |
High Precision Forged Gear for Wind Turbine Main Gearbox Drive System Components |
| Material Grades |
- 18CrNiMo7-6, 20CrMnMo, 42CrMo4 alloy steels for high torque and long fatigue life- Materials chosen for superior wear resistance, hardenability, and dimensional stability under fluctuating wind loads |
| Forging Equipment |
- Hydraulic Hammers: 5T, 8T, 12T- Open-die forging and precision preform forging for large-diameter wind turbine gearbox gears- Ensures continuous grain flow and improved impact resistance |
| Manufacturing Process |
Precision Forging → Normalizing / Quenching & Tempering → Rough Machining → CNC Gear Hobbing / Shaping → Carburizing / Case Hardening → Gear Grinding → Final Machining → Tooth Contact & Dimensional Inspection |
| Forging Ratio |
≥ 4.0 — Provides refined grain structure, excellent fatigue resistance, and enhanced structural integrity across millions of operating cycles |
| Heat Treatment Options |
- Carburizing + Quenching + Tempering for hard tooth surfaces and tough gear core- Selective induction hardening for load-bearing areas- Stress relieving and precision tempering for dimensional stability- Optional surface enhancement to minimize micropitting |
| Applications |
- Main gearbox stage gears for 1.5MW–8MW wind turbines- High-torque speed-increasing gear sets- Power transmission modules requiring high accuracy, low noise, and long service life in onshore/offshore wind farms |
| Process Compliance |
Conforms to IEC wind turbine gearbox standards, AGMA gear accuracy classifications, and customer-specific wind power engineering requirements |
| Delivery Conditions |
- Heat-treated and supplied as rough-machined blanks or fully finished precision-ground gears- Optional anti-corrosion coating for offshore storage and transportation |
| Testing & Inspection |
- Chemical Composition Analysis- Mechanical Properties: Yield Strength, Tensile Strength, Impact Toughness, Hardness Profile- Non-Destructive Testing: UT, MT, surface flaw detection- Gear Accuracy Measurement: Tooth profile, lead, contact pattern, backlash, dimensional accuracy (AGMA/ISO) |
Process Flow:
Initial raw material confirmation → organized unloading and safe handling → detailed dimensional and surface quality check → uniform preheating to forging temperature → precision forging operations → heat treatment to achieve required mechanical performance → continuous quality monitoring during processing → rough machining of forged parts → non-destructive testing to detect internal or external defects → final accuracy and quality inspection → corrosion-protected packing → dispatch to customer.
Frequently Asked Questions (FAQs) – Differentiated Version
1. What is the range of forgings you can produce?
Our production capability covers forged parts from around 100 kg up to 7,000 kg, suitable for both medium-sized assemblies and large, high-load industrial equipment.
2. Do you offer heat treatment and machining services?
Yes. All heat treatment processes are carried out in-house, and we can supply components as rough-machined blanks or fully finished precision-machined parts, depending on customer requirements.
3. Which industries commonly use your products?
Our forgings are widely applied in wind power, heavy machinery, port handling systems, transmission equipment, mining, construction, and other demanding industrial sectors.
4. What are your normal delivery lead times?
-
Items in stock: about 30 days
-
Custom-made forgings: generally 40–45 days, depending on design complexity, material grade, and order quantity
5. Where is your manufacturing facility located?
Our plant is located in Changzhou, Jiangsu Province, with convenient access to Shanghai Port, enabling efficient international shipping.
Request a Quote
Please provide your technical drawings and specific requirements.
Our engineering team will review the information and offer a prompt, customized quotation and technical solution.
Twoja wiadomość musi mieć od 20 do 3000 znaków!
