Gear Manufacturing

Thanks to advanced, highly versatile Multi-Tasking machines paired with the right software and CAD/CAM system, production of gears of all shapes and sizes is faster and more precise than ever before.

Our large selection of more than 90 configurations of Multi-Tasking machines enable you to maximize your investment by machining gears in single setups and processing gear-related components, such as gearboxes, and completely different complex parts. And our SMOOTH Gear Cutting Solutions modules increase gear machining accuracy and productivity through graphical user interfaces for gear/spline data entry along with cutting parameters for writing programs within a matter of minutes.

SMOOTH Gear Cutting Solutions

SMOOTH Gear Cutting Solutions

SMOOTH Gear Cutting Solutions employ graphical user interfaces for gear/ spline data entry along with cutting parameters for writing programs within a matter of minutes.

SMOOTH Gear Cutting Solutions include three modules:

SMOOTH Gear Milling

Our Multi-Tasking machines equipped with secondary spindles and lower turrets for simultaneous gear milling and turning operations improve throughput for production of OD parallel axis gears. Standard milling cutters such as end mills and ball mills make a series of progressive cuts along the tooth profile to create the involute form.

SMOOTH Gear Hobbing

Create quick, highly accurate OD gears and splines at AGMA 8-10 quality levels with our Multi-Tasking machines with the correct hobbing cutter and synchronizing the turning and milling spindle rotations.

SMOOTH Gear Skiving

With our SMOOTH Gear Skiving module, our Multi-Tasking machines can perform skiving operations to quickly produce accurate OD and ID parallel-axis gears (spur and helical) and splines in single setups.

CAM Surfacing

CAM Surfacing

Surfacing operations performed on our Multi-Tasking machines with 5-axis capabilities produce precision gear tooth surfaces, both to a critical size and the required surface finish. Surfacing on a 5-axis machine does not involve special gear options or gear tooling, but rather standard cutters like end mills and ball mills and modern processing solutions, such as 3-D solid gear modeling software, CAD/CAM systems and post processors to format G-code.

Closed-Loop Gear Machining

Closed-Loop Gear Machining


Mazak, Dontyne Systems, Renishaw and Advanced Industrial Measurement Systems (AIMS) collaboratively developed a flexible gear machining solution that combines the Multi-Tasking capabilities of Mazak’s precision 5-axis CNC Multi-Tasking machine tools, Dontyne Systems’ gear production software solutions and Renishaw’s and AIMS’ inspection equipment. The process is suitable for manufacturing spur and helical, bevel or spline gears using either standard tooling, such as end mills, or custom tooling, such as gear hobs.

Closed-Loop Gear Machining enables customers to use Mazak’s Multi-Tasking CNC machine tools to accurately cut gears that have been designed using Dontyne’s software. The software functions include powerfully integrated graphics and industry standard engineering reports that enable a gear manufacturer to simulate how gear sets make contact for different industry applications.

The validated closed-loop process adjusts the finish part program to account for any manufacturing errors. A single machine tool cuts many gear types and sizes as well as produces a variety of non-gear parts. Closed-Loop Gear Machining offers a significant savings of investment and increase of flexibility over dedicated gear-making solutions that are only capable of producing gears of one size.

Want more information on this exciting application? Contact our Applications department at 859-342-1700.