Hansheng Automation (Dongguan) Co., Ltd. is one of the most experienced manufacturers and suppliers of ISO 5 Precision Custom Metal Worm Gear Sets in China. If you're going to wholesale bulk cost-effective ISO 5 Precision Custom Metal Worm Gear Sets made in China, welcome to get pricelist and quotation from our factory. Also, customized service and OEM&ODM service are available.
Hansheng specialize in manufacturing ISO/DIN Grade 5 precision worm gears tailored for critical performance environments. From micro-modules as small as 0.1 to robust 5.0 module drive systems, our custom metal worm gear sets ensure zero-backlash capabilities and whisper-quiet operation.
What does Custom Metal Worm Gear Set include
1. Worm Wheel (Worm Gear)
Material Selection: Typically Phosphor Bronze (such as CuSn12, PB1, or QSn10-1) or Aluminum Bronze (such as CuAl10Fe3Mn2). For specialized medical, food-contact, or lightweight applications, engineering plastics like POM (Acetal) and FDA-compliant Nylon are also available.
Material Hardness: For phosphor bronze alloys, hardness is maintained within HB 90~120; for aluminum bronze (e.g., CuAl10Fe3Mn2), it typically reaches HB 150~180 to meet heavy-load demands.
Manufacturing Process: Following blank forging, the tooth profile undergoes rough hobbing as a pre-machining step, followed by high-precision finish power skiving on a Kashifuji KPS30 CNC Vertical Skiving Machine (Japan). This advanced skiving process ensures superior tooth surface integrity, significantly reduces pitch errors, and achieves a finer surface finish compared to conventional hobbing.
2. Ground-Thread Worm Shaft (Worm Screw)
High-Strength Alloy Steels: Typically manufactured from premium case-hardening steels such as 20CrMnTi, 18CrNi8, SCM415, or AISI 8620.
Heat Treatment and Surface Hardness: The worm shafts undergo precise carburizing and quenching (or gas nitriding), achieving a surface hardness of HRC 58 to 62 while maintaining a tough, ductile core to resist torsional and fatigue stresses.
Precision Thread Grinding: After heat treatment, the thread profile is finished on CNC thread grinding machines. This process controls cumulative lead error (Fl) and profile deviation (ffα), and reduces surface roughness to Ra 0.4 micrometers (um) or better (with options down to Ra 0.2 um).
Product Features
ISO/DIN Grade 5 precision, with backlash down to <3 arcmin on request-ideal for indexing tables and rotary drives. Worm wheels are finish-skived on a Kashifuji KPS30, while steel worms are precision thread-ground to ensure quiet, high-efficiency operation. Size range: Worm shafts Ø3–150 mm; Worm wheels Ø5–300 mm, covering micro to heavy-duty applications.
Materials: Carburized steel worms (HRC 58–62) paired with Phosphor Bronze (CuSn12) or Aluminum Bronze wheels for maximum wear resistance and anti-galling under high torque.
Technical Parameter Table
| Parameter | Worm Shaft (Worm) | Worm Wheel (Worm Gear) |
|---|---|---|
| Precision Grade | ISO/DIN GB Grade 5 (AGMA 12) [For M≥0.5; consult us for micro modules] | ISO/DIN GB Grade 5 (AGMA 12) [For M≥0.5; consult us for micro modules] |
| Module Range | 0.1 to 5.0 (Specializing in Micro-Modules) | 0.1 to 5.0 (Specializing in Micro-Modules) |
| Diameter Range (OD) | Ø 3 mm - Ø 150 mm | Ø 5 mm - Ø 300 mm |
| Teeth / Starts | 1 to 6 Threads (Starts) | 10 to 58 (Custom) |
| Worm Profile Type | ZI / ZA / ZK (Customizable) | Matched to Worm Profile |
| Core Machining Process | CNC Turning, Thread Milling, Thread Grinding (Ra 0.4 um) | CNC Hobbing [M<0.8]; Precision Skiving (Kashifuji KPS30) [M≥0.8] |
Application Areas
Precision Instruments
Precision worm gears for lithography machine workbenches (positioning error < 10 μm), rotary axis drive solutions for coordinate measuring machines, 5-grade precision to meet high-precision positioning requirements, compatible with semiconductor packaging equipment and lithium-ion battery electrode sheet cutting equipment (high-speed operation noise < 60 dB).
Medical equipment
Surgical robot joints, CT scanner rotary mechanism-specific worm gears, with optional FDA-standard oil-free lubricated nylon worm gears to meet medical cleanroom environment requirements.
Aerospace
Satellite antenna drive lightweight aluminum bronze worm gears (40% lighter than steel components), drone servo motor transmission worm gears, with vibration-resistant design suitable for aerospace conditions.
Non-standard applications
Electric vehicle reducers (customized large module 2.5mm + high reduction ratio 50), marine engineering anti-salt fog coating worm gears, heavy-duty machine tool spindle phosphor bronze worm gears (anti-seizing design).
Robotics & Automation
Low-backlash gear sets for robot joints and pick-and-place mechanisms.
Manufacturing Process of Precision Worm Wheels
To help you better understand our manufacturing process, here is a brief introduction to the mechanical manufacturing process of Precision Worm Wheels.
Material & Blank Preparation
Raw bronze undergoes centrifugal casting or forging to achieve a porosity-free, dense grain structure, with composition verified by OES spectral analysis prior to machining.
Rough Machining & Datum Establishment
CNC turning of OD, face, and bore to establish precise reference datums. Sharp PCD/CBN tooling is applied to minimize cutting-induced stresses in copper alloys.
Semi-Finish Turning & Secondary Features
Semi-finish turning to remove machining allowances, followed by EDM or broaching of keyways, splines, and set-screw holes-all machined prior to final bore grinding to maintain uninterrupted clamping surfaces.
Bore Precision Grinding & Ultra-Finish Skiving
Bore and clamping faces are precision-ground to within microns to serve as the master datum. The final tooth profile is then generated on a Kashifuji KPS30 via ultra-precision skiving, removing a micro-layer to correct cumulative pitch errors.
Deburring & Matched Contact Inspection
Micro-burrs are removed for quiet meshing. Final inspection includes lead/profile deviation testing on a gear analyzer, plus a red-lead contact pattern test against the mating worm.
FAQ
Q: What is the practical difference between ISO Grade 5 and Grade 6 precision?
A: Grade 6 is 0.02mm; the tooth profile inaccuracy of a Grade 5 precision worm gear is ≤0.01mm; so, the backlash may be managed in three arc minutes. Using servo motor drives as an example, ISO 5-grade precision achieves ±0.1° (ISO 6-grade is ±0.3°), appropriate for precision applications such lithography machine stages and surgical robot joints; whereas ISO 6-grade precision is more suitable for general automation equipment.
Q: What is the minimum order quantity for non-standard customization?
A: Standard module products, non-standard modules (e.g., 0.3 mm/6 mm), or special processes (such as carburizing and quenching, Ni-P plating) all have a minimum order quantity of 5 pieces. Sample production takes 1-2 weeks, and mass production takes 2-3 weeks. Customization based on drawings or samples is supported, and rush orders are available (with samples ready in as little as 1 week).
Q: How to select worm gear material?
A: Light-load quiet applications (e.g., medical equipment, office machinery): Choose nylon worm gears (noise <55dB, self-lubricating and maintenance-free, compliant with FDA standards);
Medium-load general applications (e.g., conveyor lines, automated equipment): Choose aluminum bronze (ZCuAl10Fe3) (30% lower cost than phosphor bronze, 80% load capacity, high cost-effectiveness);
High-speed heavy-duty applications (e.g., machine tool spindles, electric vehicle reducers): Choose phosphor bronze (ZCuSn10Pb1) (friction coefficient 60% lower than cast iron, suitable for speeds >1000 rpm, strong anti-seizing capability). Q: Do you offer matching worm gear processing services?
Q: Do you provide matching worm gear processing services?
A: We offer matching worm gear processing services on the same production line, using 20CrMnTi carburizing and quenching (HRC 58-62), precisely matched to the hardness of the worm wheel tooth surface.
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