Tier 1 Automotive Supplier Needs Specialized Spur Gear Parts

Overview

Toolcraft LLC partnered with a Tier 1 automotive supplier in North Carolina to solve a critical challenge: sourcing specialized spur gear parts that were unavailable through standard supply chains. The project demonstrates Toolcraft’s ability to deliver precision-engineered solutions when off-the-shelf options fall short.

Customer Profile

• Industry: Automotive / Heavy Trucking
• Location: North Carolina
• Customer Type: Tier 1 Automotive Supplier
• Challenge: Required specialized spur gear parts unavailable from existing vendors; previous attempts to source these components resulted in “No Quotes.”

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Toolcraft was tasked with manufacturing custom spur gear parts. Each part required custom machining to meet the customer’s exact specifications, as standard catalogs and suppliers did not offer a solution.

The supplier faced the following unique challenges:

• Non-standard components: Needed gear parts that did not exist as off-the-shelf products.
  Speed to solution: Delays from prior sourcing attempts created pressure to find a reliable partner.
• Legacy documentation: Only outdated prints existed for reference. Toolcraft had to translate these into actionable manufacturing plans.

To provide a cost-effective and precise solution, Toolcraft employed Electrical Discharge Machining (EDM) instead of traditional hobbing. This decision offered several advantages:

• Cost savings: EDM eliminated the expensive setup costs associated with gear hobbing.
• Accuracy: EDM enabled precision cutting of gear profiles based on outdated prints.
• Efficiency: Toolcraft quickly prepared metal blanks, processed them through EDM, and performed additional finishing operations.

• Prepared blanks for all gear details.
• Drilled and jig-ground the crosshole after EDM cutting.
• Applied black oxide coating for corrosion resistance and durability.
• Conducted inspection using Toolcraft’s standard quality protocols to ensure compliance with customer standards.

Two of the gears produced illustrate the complexity of the project:

• Teeth: 30
• Pitch Diameter: 95.25 mm (3.750 in)
• Pressure Angle: 20°
• Gear Type: External

• Teeth: 16
• Pitch Diameter: 50.80 mm (2.000 in)
• Pressure Angle: 20°
• Gear Type: External
• Notable Feature: Undercut design required for proper meshing.

By leveraging its precision machining expertise, Toolcraft enabled the Tier 1 supplier to:

• Reduce Costs: Avoided high tooling expenses associated with traditional gear hobbing.
• Extend Equipment Life: Delivered replacement parts compatible with existing systems.
• Overcome Supply Chain Barriers: Successfully sourced parts after others had declined to quote.
• Ensure Reliability: Maintained consistent quality through rigorous inspection and finishing processes.

When faced with unavailable, non-standard gear components, the Tier 1 automotive supplier turned to Toolcraft LLC for a solution. Through innovative use of EDM machining, Toolcraft not only delivered the specialized spur gear parts but also provided cost savings, precision, and a dependable supply line for critical components.