Milwaukee Gear Logo

THE ART OF PERFORMANCE GEARING
POWERED BY EXPERIENCE


ART IN MESH WITH SCIENCE...

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The Milwaukee Gear custom steel gears, pinions and assemblies for OEM market leaders require case hardened helical and spur ground tooth
gears to exacting specifications with traceability and reliable lead times. We help our customers to be successful with design assistance and process engineering
optimization. Our engineering talent, on-site heat treatment capabilities and passion for excellence for over 90 years have earned a sustained customer base.

 

WE CAN SERVE YOUR SPECIFIC NEEDS

Basic

  • Part to print.
  • Heat treatment.

Advanced

  • Precision gear and pinion manufacturing.
  • Optimizing current designs.
  • Partner to develop new more cost effective torque dense designs.
  • Bundle multiple components into a sub-assembly to reduce number of vendors.
  • Providing repair services.

Service

  • Field monitoring & diagnostics.

CONSISTENT PROCESSES, INTERNALLY CONTROLLED

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MILWAUKEE GEAR PRODUCTS

  • External gears.
  • External gear assemblies.
  • Internal gears.
  • Pinions.
  • Pinion assemblies.
  • Double helical.
  • Specialty parts.
  • Rapid prototypes.
  • Custom gearboxes.
  • In-house heat treat.

 

 

 

 

ADDITIONAL SERVICES

TYPICAL GEAR SPECIFICATION OUTLINE

  • 8620 bearing quality steel.
  • Carburized, die quench and ground.
  • AGMA class 12.
  • Rating reviewed for target design life.


 

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Kop-Flex® repair services, supported by
Regal® Perceptiv Technologies

  • Tools and techniques used to measure the performance of a
    customer’s application.
  • Training conducted at customer location, off-site or factory.
  • Assist customers in reviewing application needs and help select
    appropriate products.
  • Will provide a product manager, general contractor or consultant
    for the installation as well as additional labor.
  • Electrical power monitoring, mechanical torque/power monitoring,
    thermal conditioning, ultrasonic measurement monitoring.
  • Repaired/refurbished products come with a factory warranty at a
    fraction of the price of a new product.

 

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GEAR TESTING CAPABILITIES

  • State of the art gear inspection equipment.
  • Automated nital etch system, fully submerged.
  • Microhardness testing.
  • Carbon analysis.
  • In-house destructive and non-destructive testing.
  • Full metallurgical lab.
  • On-staff metallurgist.
  • Reverse engineering and design optimization via KISSsoft and LVR.


SUMMARY OF KEY CAPABILITIES

DESIGN AND OPTIMIZATION

  • Design optimization using state-of-the-art gear software.
  • Engineering experience to troubleshoot application and performance problems, professional failure analysis.
  • Automated pricing.
  • Fast response.

EXPERIENCE WITH THE TOTAL PROCESS
PROVIDES...

  • Proper tooth cutting to anticipate distortion.
  • Proper uniform case depth.
  • Proper transition to Root, no stress risers.
  • Optimized performance and life.

 

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GEAR MANUFACTURING & INSPECTION

  • Hobbing & grinding capacity to 78” OD.
  • In-house heat treatment.
  • AGMA Class 10 to 15.
  • Precision gear geometry measurement and documentation.
  • Large Kop-Flex® couplings, spindles, and U-joints.
  • Full nital etch inspection to ensure no grinding burns.

 

 

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EXTERNAL GEARS

  • Pitch: 48 to 0.5 DP (0.53 to 50.8 Module).
  • Narrow gap spur, helical and double helical.
  • Quality levels to AGMA Q15/A2/ISO A2.
  • Maximum gear grinding diameter to 78 inches OD.
  • Specializing in Carburized and Die Quenched Gears.

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EXTERNAL GEAR ASSEMBLIES

Assembly Options:

 

  • Bolted Together.
  • Shrink Fit.
  • Electron Beam Welding.
  • Dynamic balancing.
  • Static Balancing.
  • Gear face angle grinding.

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INTERNAL GEARS

Pitch: 48 to 1 DP
(0.53 to 25.4 Module)

 

  • Milling up to 49 inches.
  • Shaper Cutting up to 50 inches.
  • Quality Levels to AGMA Q15/A2/ISO A2.
  • Spur and Helical.
  • Gear grind up to 78 inches OD.
  • Broach up to 80 tons.

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PINIONS

Milwaukee Gear has the technology to manufacture extremely critical
high-speed pinions which operate at speeds that require near
perfect machining

 

  • Spur and Helical
  • Pitch: 48 to 0.5 DP (0.53 to 50.8 Module)
  • Manufacture up to 80 inches in length
  • Quality Levels to AGMA Q15/A2/ISO A2

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PINION ASSEMBLIES

Our Capabilities Include:

 

  • Hard Chrome Plating
  • Thin Dense Chrome Plating
  • Dynamic Balancing
  • Electrical Run Out Compensation
  • Proficient with high alloy metals
  • Timed Double Helical Pinions, Keyed, Splined, or EB Welded

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HIGH SPEED

  • We have the capabilities to manufacture high precision
    gears for dependable performance and service life.
  • Proficient in face angle grinding on pinions and gears.
  • Our progressive production techniques provide high precision
    gears with speeds up to 70,000 RPM.

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DOUBLE HELICAL

The narrow gap double helical option provides 20% more rating
than spur gear with no induced thrust

Assembly options:

 

  • Electron Beam Welding.
  • Option to Herringbone gear is a bolted design with no gap
    between LH & RH gears.
  • Design assistance is available to identify optimum
    configurations and size.

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SPECIALTY PARTS

Milwaukee Gear is not limited to traditional gear configurations.
We have the ability to manufacture precision parts beyond gearing.

Examples:

 

  • Carriers
  • Couplings
  • Shafts
  • Clutches

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RAPID PROTOTYPES

Using six sigma lean tools focusing on time, money & waste
we established a Rapid Prototype program. Through process driven
solutions & team commitment, we offer quick deliveries when needed.
This new 4140 rolled ring nitrided spur gear assembly with 5 module
& 445 mm pitch diameter was shipped in 6 weeks.

 

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CUSTOM GEAR BOXES

Manufactured to Customer Specifications
Specializing in Planetary Configurations
Assist with Gear Design, Optimization and Rating

Custom precision turn-key designs that include:

 

  • Gearing
  • Housing
  • Bearings
  • Shafts
  • In-house spin test

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HEAT TREATMENT SERVICES

CASE HARDENING

  • Case Carburizing
  • Carbonitriding
  • Nitriding

QUENCHING

  • Hot oil
  • Fast oil
  • Polymer
  • Water

CONTROLLED ATMOSPHERE

  • Hardening 
  • Normalizing
  • Annealing
  • Stress relieving
  • Tempering

 

METALLURGICAL LAB CAPABILITIES

  • Cutting/mounting and polishing equipment
  • Carbon Analyzer
  • Spectrometer
  • Automated micro-hardness tester
  • Microscope
  • Micro hardness testing

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HEAT TREATMENT FACILITIES

EXPERIENCED WITH

  • Gears
  • Electrical Components
  • Cam Shafts
  • Large Castings
  • And many more…
 

OTHER CAPABILITIES

  • Two row pusher with 36x36”.
  • Gas nitride 40x50”.
  • Die quench presses up to 48” in diameter.
  • Rotary furnace.
  • Roller hearth furnace (reheat or normalize).
  • Pit carburizes.
  • Normalize pit furnace - 30,000# load capacity.
  • Open fire tilt-up furnace, 72x96” tray size
  • Super 36 integral quench furnaces 36x72x36”.
  • Straightening up to 300 ton.
  • Shot Blast.

 

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REPAIR SERVICES

SPINDLE AND U-JOINT REPAIR

  • 30 ton crane capacity.
  • Clean/degrease equipment.
  • Repair/upgrade.
  • We repair all brands.
  • Continuous lube spindle capabilities.

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GEARBOX REPAIR/UPGRADE

  • Reverse engineering.
  • Coupling mounting.
  • Motor mounting.
  • We repair all brands.






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INDUSTRY APPLICATIONS

METALS

  • Gearbox and coupling repair and upgrade.
  • Reverse engineering.
  • Coupling mounting.
  • Motor mounting.
  • We repair all brands.

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TURBO-MACHINERY

  • Oil-free, air and gas, integrally geared compressors.
  • Single & Multi- Stages, API 617 compliant.
  • Gear rotary positive displacement blowers.
  • Oil-free rotary lobe gas screw compressors.
  • High-performance couplings and complete high-speed gearboxes.

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HOISTS AND LIFTS

  • Ladles.
  • Cranes.

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LIGHT AND HEAVY RAIL

  • Main propulsion.
  • Pinion and gear assemblies.

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ENERGY

  • Stimulation & Fracturing Pumps.
  • Drilling Pumps / Mud Pumps.
  • Well Service Pumps.
  • Wind power.

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HEAVY INDUSTRIAL

  • Paper.
  • Shaker screens.
  • Marine propulsion.
  • Beam pumps.
  • Mining.off-road.

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GENERAL INDUSTRIAL

  • Meat grinders.
  • Plastic extrusion.
  • Shredders.
  • Mixers.

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