Zinc Alloy Die-Cast Gears and Transmission Parts

Core strengths
Core Process Advantages

Precision Die-Casting Technology
Equipment Configuration:
Hot Chamber Die-Casting Machines: 80T-500T
Precision Die-Casting Machines
Vacuum-Assisted System (optional)

Mold Technology:
Gear-Specific Mold Design
Mold Life: ≥150,000 cycles
Mold Temperature Control Accuracy: ±2°C
Optimized Venting System Design

Precision Post-Processing
Deburring Process:
Vibration Polishing Deburring
Chemical Deburring
Manual Fine Trimming

Gear Fine Machining:
Gear Hobbing (optional)
Gear Sharpening
Gear Surface Polishing

Heat Treatment:
Surface Passivation Treatment
Electroless Nickel Plating (Improves Wear Resistance)
Dacromet Coating (Corrosion Resistance)
Quality Control System

Dimension Inspection:
Gear Inspection Center: Checks Gear Profile, Tooth Orientation, Tooth Pitch
CMM Measurement: 100% Inspection of Key Dimensions
Projector Inspection: Profile Accuracy Control

Performance Testing:
Noise Testing: ≤45dB (at 1-meter distance)
Service Life Testing: ≥10⁶ Cycles
Torque Testing: Load Capacity Verification
Dynamic Balance Testing: High-Speed Stability

Technical Advantages of Zinc Alloy Gears

Economic Advantages
Low Mold Cost: 40% lower than powder metallurgy mold costs
High Production Efficiency: Short die-casting cycle, suitable for mass production
High Material Utilization: ≥95%, reducing material waste
Overall Cost Advantage: 50-70% lower than machined gears

Performance Features
Good Vibration Damping: Zinc alloy's damping properties help reduce noise
Excellent Castability: Capable of producing complex, integrated gear components
Adequate Mechanical Properties: Tensile strength 200-380MPa, suitable for most light-load applications
Good Surface Quality: Die-cast surface roughness Ra1.6-3.2μm

Design Flexibility
Complex Structure Integration: Can integrate features like hubs, ribs, etc.
Multiple Surface Treatment Options: Electroplating, Electroless Plating, Passivation, etc.
Lightweight Design: Density 6.6g/cm³, 60% lighter than steel gears
Rapid Prototyping: Sample cycle only 7-10 days

Core Product Introduction

Product Series and Technical Specifications

Precision Spur Gear Series
Size Range:
Module: 0.3-2.0
Diameter: φ5-φ120mm
Number of Teeth: 10-120 teeth
Thickness: 2-30mm

Accuracy Grade:
Standard Precision: ISO 9-10 grades
Precision Grade: ISO 8 grade (special requirements)
Tooth Profile Error: ≤0.02mm
Tooth Pitch Cumulative Error: ≤0.05mm

Material Selection:
Zamak 3: General-purpose, good fluidity
Zamak 5: High strength, excellent wear resistance
ZA-8: Good high-temperature performance
Eco-friendly Zinc Alloy: Compliant with RoHS standards

Worm and Worm Gear Drive Components
Technical Features:
Self-locking function enables high reduction ratios
Smooth transmission, noise less than 45dB
Efficiency up to 70-90%

Performance Parameters:
Module: 0.5-1.5
Reduction Ratio: 5:1 to 60:1
Load Capacity: 0.1-5 N·m
Operating Temperature: -20°C to +100°C

Bevel Gears and Hypoid Gears
Application Scenarios:
Directional transmission systems
Transmission layouts in space-constrained environments
Applications requiring 90° transmission

Technical Capabilities:
Spiral Angle: 0°-45°
Axis Angle: 90° (standard), other angles can be customized
Surface Finish: Ra≤1.6μm
Heat Treatment: Surface hardening optional

Planetary Gear Assemblies
Assembly Advantages:
Compact structure, large load-bearing capacity
Wide transmission ratio range
Smooth operation, low noise

Supporting Services:
Full set of sun gears, planet gears, and internal gears
Pre-assembly testing of components
Lubrication scheme recommendations
Special Transmission Components

Product Types:
Sprockets: Pitch 3.175-12.7mm
Timing Pulleys: MXL, XL, L, H types
Cam and Eccentric Wheels
Ratchets and Pawls

Application Scenarios

Office Automation Equipment
Typical Applications:
Printer gear assemblies
Scanner drive systems
Copier paper feeding mechanisms
Shredder drive components

Technical Requirements:
Low noise: ≤40dB
Long service life: ≥5 million cycles
Precision transmission: High positioning accuracy
Home Appliances

Product Range:
Washing machine timer gears
Air conditioner louver mechanisms
Power tool drives
Small kitchen appliance gears

Performance Requirements:
Corrosion resistance: Suitable for humid environments
Safety and reliability: Prevent accidental failures
Cost control: Competitive pricing for large quantities
Automotive Parts

Application Components:
Wiper transmission gears
Window regulators
Seat adjustment mechanisms
Instrument pointer drives

Industry Standards:
Compliant with automotive industry quality requirements
Passes relevant durability tests
Meets temperature cycling requirements
Industrial Automation

Usage Scenarios:
Small gear reducers
Conveyor drive gears
Valve actuators
Measuring instrument drives

Special Requirements:
Adequate load-bearing capacity
Smooth operation
Ease of maintenance

Technical Support and Services

Service Process

Phase 1: Requirements Analysis (1-3 days)
Confirmation of transmission parameters (gear ratio, torque, speed, etc.)
Analysis of installation space and connection methods
Assessment of operating environment and lifespan requirements

Phase 2: Design and Quotation (3-5 days)
Gear parameter design and calculation
3D modeling and finite element analysis
Mold scheme and cost evaluation
Sample schedule preparation

Phase 3: Sample Verification (10-15 days)
Mold manufacturing and trial molding
Sample production and testing
Performance testing and verification
Customer confirmation and feedback

Phase 4: Mass Production (As per order schedule)
Raw material procurement and inspection
Die-casting production and quality control
Post-processing and packaging
Timely delivery and logistics

Phase 5: Continuous Improvement
Collection and analysis of quality data
Process optimization and improvement
Regular customer follow-up
Technical upgrade services

FAQ

Q: What is the maximum load-bearing capacity of zinc alloy gears?
A: Depending on the modulus and size, zinc alloy gears can generally bear torque from 0.5 to 50 N·m. Specific capacity needs to be evaluated based on application.

Q: What is the highest accuracy level achievable?
A: Standard accuracy is ISO 9-10 grade, and for special requirements, it can reach ISO 8 grade.

Q: Is post-processing required?
A: Die-casting can meet the requirements of most applications. For high-precision applications, gear hobbing and precision finishing can be chosen.

Q: What is the temperature tolerance of the gears?
A: The typical operating temperature range is -20°C to +120°C. Special alloys can withstand temperatures up to +150°C.

Q: Can surface hardening be done?
A: Yes, we provide surface hardening treatments such as chemical nickel plating to improve wear resistance.

Q: What is the minimum order quantity?
A: There is no MOQ for samples. Mass production generally starts from 5000 pieces.

How to Get Samples and Quotes

We offer free sample services, allowing you to experience the quality of our products firsthand:

Sample Request Requirements
Gear parameters (modulus, number of teeth, pressure angle, etc.)
Operating conditions (torque, speed, lifespan requirements)
Installation interface requirements
Surface treatment requirements

Quick Quote Channel
Submit gear parameters online, and receive a reply within 24 hours
One-on-one communication with technical engineers
Provide a comparison of cost optimization solutions