0.05mm Fine Wire Slow Wire Processing Gears

Processing advantages

The 0.05MM fine wire slow wire cutting technology combines the characteristics of "high precision in fine wire processing" and "high efficiency with moderate wire diameter". Compared with 0.03MM fine wire, it is more suitable for mass production, and compared with the conventional 0.1MM and above fine wire, it has better precision. The core advantages are as follows:

- High-precision tooth forming: 0.05mm Fine Wire Slow Wire Processing Gears can precisely process gears with modules of 0.15-1.5. The minimum processed tooth thickness reaches 0.08MM, and the tooth profile error is controlled within ±0.003MM. It is perfectly compatible with common tooth profiles such as involute and modified gears. Solve the problem of "difficulty in balancing precision and efficiency" for medium and small module gears.

- High-quality surface and mass production compatibility: The surface roughness of the gears after processing is as low as Ra0.2μm, which can meet the transmission requirements without secondary treatment. Meanwhile, the moderate wire diameter increases the single processing efficiency by 40% compared to 0.03MM fine wire, making it suitable for batch orders of over a thousand pieces per month.

- Efficient processing of complex structures: Supports integrated processing of composite structure gears with steps, keyways, and weight reduction holes, reducing the number of clamping times. The consistency error of processing accuracy is ≤0.004MM, especially suitable for the integrated component requirements of automotive electronics and automation equipment.

Key processing parameters

Quality control

0.05mm Fine Wire Slow Wire Processing Gears Processing flow and quality control with "stable batch accuracy" as the core, establish a standardized control process to ensure consistent product quality in each batch.

1. Drawing analysis and process standardization: Engineers analyze the 2D/3D drawings of gears, formulate standardized wire feeding paths and discharge parameters based on batch requirements, and generate reusable processing technology packages

2. Batch clamping and precise tool setting: Multi-station fixtures are adopted for batch clamping, and an automatic tool setting system is used to achieve ±0.002MM level tool setting accuracy, reducing clamping errors

3. Segmented processing and sampling inspection: A two-stage processing method of "rough cutting - fine cutting" is adopted. Every 20 pieces are sampled and inspected by a two-dimensional image measuring instrument, and the processing parameters are calibrated in real time to ensure batch consistency

4. Full inspection of finished products and batch traceability: 5% of each batch of finished products are randomly selected for full-size three-coordinate inspection, and batch inspection reports are issued. Batch numbers are laser-engraved for easy traceability

Application field

In the field of automotive electronics: We customize 0.3 module stainless steel gears for on-board radar systems, with a pitch error of no more than 0.005MM, to meet the stability requirements of the on-board environment. The monthly supply volume is 2,000 sets

In the field of automation equipment: Customize 45# steel gears with a module of 1.0 for servo motors, with a surface roughness of Ra0.2μm, to ensure smooth transmission during equipment operation

In the field of precision instruments: 0.05mm Fine Wire Slow Wire Processing Gears can customize aluminum alloy double gears for detection equipment. They are processed in one piece with 0.05MM fine wire, reducing the weight by 30% and meeting the lightweight requirements