We need a bevel gear pair at a non-standard shaft angle of 75° with a ratio of 2.5:1. How do we calculate and specify this, and can Korea Ever-Power manufacture it?

Non-standard shaft angle bevel gear design is straightforward geometrically but requires care in specifying the pitch cone angles. For shaft angle Σ = 75° and ratio i = 2.5:1 (z₂/z₁ = 2.5): the pitch cone angles are calculated from: tan(δ₁) = sin(Σ) / (i + cos(Σ)) = sin(75°) / (2.5 + cos(75°)) = 0.9659 / (2.5 + 0.2588) = 0.9659 / 2.7588 = 0.3502, giving δ₁ = 19.3° (pinion pitch cone angle). δ₂ = Σ − δ₁ = 75° − 19.3° = 55.7° (wheel pitch cone angle). The remaining design parameters (module selection from the ISO 6336 bevel gear strength calculation, face width, tooth count, helix angle if spiral bevel) follow the same procedure as for 90° bevel gears once the pitch cone angles are established. Korea Ever-Power can design and manufacture this gear pair from the application data (torque, speed, duty cycle, material constraint) — provide the shaft angle, ratio, and the torque and speed of the faster (pinion) shaft, and Korea Ever-Power will complete the design calculation and provide a dimensional drawing for customer approval before manufacture. Lead time after drawing approval: 18–25 days for M4–M8 spiral bevel in 20CrMnTi. Non-standard shaft angles add no manufacturing difficulty for spiral bevel gears on CNC gear-cutting machines — the pitch cone angle is a programmed parameter, not a physical machine setting that requires hardware change.

Our production volumes are low — only 50 bevel gear pairs per year for a specialist machine. Is custom manufacturing viable at this volume, or should we look at modifying a catalogue bevel gear?

50 pairs per year (100 gears) is a viable volume for Korea Ever-Power custom bevel gear manufacturing — this volume is above the minimum that allows the setup cost to be amortised to a commercially reasonable per-piece price, and below the threshold where high-volume production tooling (dedicated cutting and grinding fixtures) would be justified. The practical comparison between custom manufacture and catalogue modification for 50 pairs/year: (1) Catalogue modification (bore the catalogue gear to a custom bore size, add keyway, modify the OD): viable if the ratio and module of a catalogue gear match your requirement and only the bore/keyway differs. Catalogue bevel gears are available in limited ratio/module combinations — if your requirement is an uncommon ratio (e.g. 2.3:1) or an unusual module (e.g. M7), no catalogue gear will match, making modification impossible. (2) Custom manufacture from blank: viable for any ratio, module, and shaft angle. At 50 pairs/year, Korea Ever-Power amortises the CNC setup over 50 parts — for M5 spiral bevel at 50 pairs/year, the setup cost represents approximately €8–15 per pair, which is a small fraction of the total gear price. Korea Ever-Power offers open pricing transparency for low-volume custom bevel OEM: the quotation breaks down the material cost, machining cost, heat treatment cost, quality inspection cost, and setup amortisation separately — the customer sees exactly what each element costs and can make an informed decision. For volumes below 20 pairs/year, prototype pricing applies (setup not amortised, higher per-piece price) — at which point catalogue modification becomes more cost-competitive if any catalogue option is dimensionally compatible.

What information must I provide to Korea Ever-Power to start a custom bevel gear project, and what is the process from first contact to first delivery?

The minimum information required to start a custom bevel gear project at Korea Ever-Power: (1) Application description: what machine/equipment the gear will be used in, what it drives, and what the operational environment is (temperature range, exposure to moisture or chemicals, cleanroom or food zone requirements). (2) Shaft angle: the angle between the input and output shaft axes (90° for a standard right-angle drive, or specify the non-standard angle if applicable). (3) Ratio: the required speed ratio (input speed ÷ output speed). If the ratio is not precisely defined, provide the input and output speeds separately. (4) Input shaft torque and speed: the maximum continuous torque (Nm) and speed (RPM) at the driving pinion shaft, and the peak or starting torque if it exceeds the continuous torque by more than 50%. (5) Dimensional constraint (if any): maximum OD, maximum face width, or mounting distance between gear centres, if the housing has a fixed geometry that the gear must fit. If no dimensional constraint exists, Korea Ever-Power designs the optimal gear size from the torque and speed data. Process after enquiry receipt: (a) Korea Ever-Power acknowledges within 24 hours and requests any missing data. (b) Application engineering review: 5–7 working days — produces a recommended specification and preliminary gear drawing. (c) Customer review and approval of the specification. (d) Quotation: issued simultaneously with the specification. (e) Order confirmation: customer issues purchase order against the quotation. (f) Manufacturing: commences on receipt of order confirmation and drawing approval — lead time as stated in the specification. (g) Quality inspection and contact pattern test. (h) Documentation package assembly. (i) Shipment with full documentation. Korea Ever-Power assigns a dedicated project engineer to each custom bevel gear project — the customer has a single named contact from enquiry to delivery.

Spur Gears

Custom OEM · any module · M1–M20

Helical Gears

Custom double-helical · OEM · any ratio

ベベルギア

Custom · any angle · M1–M20 · OEM

Worm Gears

Custom worm · any ratio · OEM design

Ring Gears

Custom internal ring · any OD · OEM

Planetary Gears

Custom kit · OEM design · compact

Plastic Gears

Custom nylon · PEEK · any module