Transmission Gears

Transmission gears operate under high torque and dynamic loads, generating substantial contact stresses on the tooth surfaces. To manage these forces, gear geometry is optimized by precisely calculating parameters such as pressure angle, module, and face width to ensure balanced load distribution across the gear teeth.

Gear Type

Spur, Helical, Double-Helical, Dog-Tooth (Synchro)

Number of Teeth

15–80 teeth (±0.2 tooth tolerance; optimized for ratio & strength)

Tooth Profile

Involute (20°–25° pressure angle); Lead crown – 0.01–0.03 mm (noise reduction)

Material Specification

Case-Hardened Steel (SAE 8620/9310), Forged Billet (4340 for racing)

Hardness & Case Depth

58–63 HRC (flanks); Core – 30–40 HRC; Case depth – 0.5–1.8 mm (carburized)

Product Description

Advanced design practices, including adherence to AGMA (American Gear Manufacturers Association) standards, are employed to evaluate bending and pitting fatigue life. These methods help maintain contact stress levels below critical thresholds, enhancing reliability and extending the service life of transmission gears in demanding operating conditions.

Surface Finish

0.2–0.4 μm Ra (ground) / 0.1–0.2 μm Ra (super-finished for NVH)

Bore Diameter/Spline

20–100 mm (±0.015 mm); 24–48 splines (DIN/SAE/ISO standards)

Dimensional Tolerances

Pitch error – ≤0.015 mm; Runout – ≤0.02 mm TIR (AGMA Class 8+)

Gear Class

AGMA 8–12, DIN 3962 Class 6–8, ISO 1328 Class 6 (performance)

Certification Standards

ISO 9001:2015, IATF 16949, AGMA 2001-D04 (gear rating)

Technical Advantages

Transmission Gears performance is critically dependent on precise adherence to nominal dimensions and profile accuracy. Manufacturing methods incorporate CNC gear hobbing, shaping, and subsequent precision grinding to control lead, profile, pitch, and runout within micrometer-level tolerances. This tight control limits profile deviations and backlash, reducing localized stress concentrations and minimizing vibration excitation. High-precision gear measuring equipment including coordinate measuring machines (CMM) and involute profile testers verify that each transmission gears meets strict geometric standards, ensuring repeatable meshing and optimal load transfer.

Fatigue failure initiates primarily at the surface or subsurface of transmission gears teeth due to cyclic loading and stress concentration at microstructural discontinuities. Surface treatments such as shot peening or laser peening induce compressive residual stresses that retard crack initiation and propagation. Controlled microstructural refinement through precise heat treatment cycles enhances core toughness and fatigue strength. Metallurgical analysis ensures grain size, hardness gradients, and retained austenite levels remain within defined limits to optimize resistance to spalling, scoring, and micro-cracking.

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Industry Applications

Automotive Passenger Vehicles

Enables precise hydraulic force transfer for effective braking response and modulation in cars, improving safety and control under varied conditions.

Commercial Trucks and Buses

Handles high braking loads by withstanding elevated pressures and temperatures, ensuring reliable stopping power for heavy-duty transport vehicles.

Construction Equipment

Handles high braking loads by withstanding elevated pressures and temperatures, ensuring reliable stopping power for heavy-duty transport vehicles.

Motorcycles and Two-Wheelers

Provides compact, lightweight piston design to deliver efficient braking force while maintaining rapid heat dissipation during frequent stops.

Industrial Machinery

Integrates with hydraulic brake systems to control motion and ensure operational safety in heavy equipment and manufacturing processes.

Railway Braking Systems

Supports robust hydraulic or pneumatic actuation, enabling controlled deceleration and emergency braking in locomotives and rail cars.

Lubrication Compatibility and Thermal Stability

Friction between mating gear surfaces generates heat that can degrade lubricant performance and lead to thermal softening of gear materials. Gear tooth surface finish is optimized with fine grinding or superfinishing to achieve low Ra values, reducing asperity interactions and lubricant film breakdown.

Noise generation results from dynamic forces caused by impact loads during gear tooth engagement. Helical and herringbone gears introduce gradual tooth engagement and increased overlap ratios that reduce impact severity and distribute forces over multiple teeth.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure the dimensional accuracy of brake caliper pistons during manufacturing?

Frigate employs precision CNC machining followed by rigorous inspection using coordinate measuring machines (CMM). This process ensures tight tolerances in diameter, roundness, and surface finish. Maintaining these parameters prevents piston leakage and ensures smooth hydraulic operation. Dimensional control at Frigate directly contributes to consistent braking performance and system reliability.

What heat treatment processes does Frigate apply to enhance piston durability?

Frigate uses controlled carburizing and tempering cycles tailored to the piston material to optimize surface hardness and core toughness. These treatments improve wear resistance and fatigue strength without compromising ductility. By balancing hardness and toughness, the pistons resist cracking under thermal and mechanical stresses. This process extends the piston’s operational lifespan in demanding braking environments.

How does Frigate address surface finish requirements to optimize piston sealing?

Frigate applies precision grinding and honing operations to achieve a low surface roughness, typically below Ra 0.4 microns. A smooth surface finish reduces friction against the piston seals, preventing wear and fluid leakage. Surface finish consistency is monitored through optical profilometry and contact profilometers. This control is crucial to maintain hydraulic system integrity and prolong seal life.

What materials does Frigate use for brake caliper pistons, and how do they impact performance?

Frigate primarily uses aluminum alloys for their lightweight and high thermal conductivity, with steel variants for high-load applications. Aluminum pistons dissipate heat rapidly, reducing brake fade during intense use. Steel pistons offer superior strength but require coatings to prevent corrosion. Material selection is matched to the application’s thermal and mechanical demands to optimize braking efficiency.

How does Frigate verify the fatigue resistance of its brake caliper pistons?

Fatigue resistance is assessed through accelerated cyclic loading tests simulating real-world braking forces and thermal cycles. Frigate uses non-destructive evaluation techniques such as dye penetrant inspection and ultrasonic testing to detect micro-cracks. Metallurgical analysis confirms proper microstructure after heat treatment. These validation steps ensure pistons withstand repeated stress without failure over time.

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10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

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