Since the late 1980s, Accurate Specialties, Inc. has become North America’s leading manufacturer of bronze gear blanking. We are an ISO 9001:2015-certified manufacturer and our cutting-edge horizontal and vertical turning centers allows us to produce bronze gear blanks with high precision and quality.
Accurate Specialties is a full-service bronze foundry that offers clients the following competitive advantages:
Reduced Total Costs
Quick Response Times
Engineering Design Assistance
Complete Material Integrity
Short Lead Times
How Are Gears Manufactured?
The most effective method for gear manufacturing depends upon a number of factors, such as manufacturer capabilities and the desired end application. There are three basic types of gear manufacturing: broaching, hobbing, and gear machining.
Manufacturers typically employ gear broaching to produce steel shafts and splines or define unusual gear shapes. Manufacturers pull the broach cutting tool through an object. As the tool is pulled through, the size of the leading edge—or tooth—gradually increases until the intended design shape is formed.
Gear hobbing produces small helical gears, spur gears, sprockets, and splines. Gear hobbing is a generating process, which means that the final tooth shape is not directly related to the shape or form of the cutting tool. The cutting tool (hob) and the workpiece are in a continual state of rotation during operations, gradually forming the gear teeth as the hob traverses the workpiece surface.
CNC gear machining is a high-precision method of forming a wide range of gears, such as internal gears, worm gears, sprockets, spur gears, and helical gears. Gear machining typically involves milling or other cutting operations.
Gear Blanks for Gear Manufacturing
Gear blanking refers to the initial metal cutting operations that form a rough material into the contour of a gear part. At Accurate Specialties, we use a number of different processes for our gear blank manufacturing. These processes include:
Chill casting:Molten bronze is poured into a die base fabricated from aluminum or steel. The lower temperature of the die causes the bronze to cool rapidly from the outside to the center. The end result is a bronze gear blank with exceptional uniformity and a particularly fine grain structure.
Centrifugal casting: Centrifugal casting produces gear blanks with very high purity levels and a fine, dense grain structure. We spin the casting die at high speeds, resulting in generated pressure up to 60 times the force of gravity. As a result, all imperfections and impurities are channeled into a centralized riser area. After it is cooled, the centralized riser material is machined out, resulting in a gear part free of shrinkage cavities, gas pockets, and blowholes.
Spin casting: In spin casting, a bronze rim encompasses a hub of steel or cast iron. Lugs in this hub are filled with molten bronze, creating the section of the blank that will form into gear teeth. Since the shrinkage rate of bronze is greater than that of cast iron and steel, the bronze mechanically bonds to the hub, creating a very strong bond.
Continuous casting: This process allows for part-specific casting. Batches of molten bronze alloy flowing through a graphite mold produce continuous cast alloys, which subsequently cool in tubes or bars.
Accurate Specialties offers a full range of casting processes to ensure the production of high-quality gear blanks for a variety of applications.
If you’re interested in learning more about the gear blanking services we offer at Accurate Specialties, Inc., reach out to us or request a quote.
Accurate Specialties is the leading manufacturer of spuncast composite gear blanks. Our spuncast gears deliver the durability and strength of bronze gears while cutting material costs via the use of steel or cast-iron center hubs. Our process and material choices offer the high level of quality and performance you expect at a much lower price point. Our spuncast composite gears are well-suited for use in most any relevant application.
Choosing Accurate Specialties for Spuncast Composite Gear Blanks
As a top manufacturer of spuncast composite gear blanks, we have learned how to make our solutions cost-effective. Our cast iron or steel center hubs we utilize are more affordable than crafting a full bronze gear blank, and without the need for spacers, our composite gears cut the need for added assembly processes. In addition, we receive a bulk discount on materials due to the high volumes of spuncast composite gear blanks that we fabricate, and these savings are passed on to our clients.
We also offer quick turnaround times for your composite gear orders. Components can be completed in as little as one week. Accurate Specialties utilizes integrated manufacturing processes to offer the manufacturing flexibility our customers demand. We guarantee the integrity of all materials, and our strict quality management process ensures a high quality end product.
Industries & Applications
Accurate Specialties’ spuncast composite gear blanks are well-suited for use in most any industry where gear blanks are used. They are relied upon in critical applications across industries such as:
We offer spuncast composite gear blanks in a range of sizes to meet the demands of most power transmission applications. We also produce bronze gear blanks that are centrifugal cast or chill cast, with a range of common and specialty alloys available.
Our gear blanks are used in the following power transmission applications:
Center point irrigation systems
Milling and manufacturing equipment
Screw conveyors and augers
CAT scanner positioning systems
Solar panel positioning systems
Our spuncast composite gear blanks can handle demanding loads placed upon them by precision machine tools while delivering sheer resistance in environments where backlash is minimal. Our gear blanks are designed for dependable operation, and made from heavy-duty materials.
You will find our gear blanks in the following machine tool applications:
Machine tool components
Rotary tables for machine tools
Indexing tables for machine tools
Our gear blanks are utilized in various marine applications, and may be customized to meet your specific design requirements.
Marine applications that have utilized our gear blanks include:
Cable & wench systems
Our spuncast composite gear blanks deliver superior reliability for the automotive industry. Components may be manufactured to meet exact specifications and are made in a variety of sizes to suit the varying needs of the automotive sector.
You can find our gear blanks in the following automotive applications:
Gear-drive power transmissions
Gear Blanks for All Industries
Accurate Specialties is an industry leader in the manufacture of reliable spuncast composite gear blanks across the above applications and many more. Request a quote today to learn how our gear blanks deliver superior performance and savings in your application.
At Accurate Specialties, Inc. (ASI) we work to satisfy our customer requests and design specifications using optimal alloys to cast a wide range of bronze gears and composite gears for a comprehensive array of applications. We work with numerous bronze alloys, each delivering desired advantages for particular operations. Our expertise guides clients in selecting the best bronze alloy for their needs.
The Copper Development Association
The Copper Development Association (CDA) works to expand the copper market worldwide through its commitment to educating producers, fabricators, and end users regarding the benefits and uses for copper and copper alloys. With a commitment to helping copper businesses thrive, the CDA supports each application where copper plays a role.
Bronze Alloys and Their Applications
Accurate Specialties, Inc. offers a wide selection of bronze alloys to serve the varying needs of our clients. Various alloys can be created specifically to meet the needs of even the most unique or demanding applications. By consulting with each client, we will determine the best choice for your intended purpose or design. Some of the most common alloys we use include:
863 Manganese Bronze
Known for its high-strength and corrosion-resistance, this bronze alloy also features durability and longevity, making it an ideal option for heavy-duty applications such as construction and agricultural equipment. 863 Manganese Bronze is popular in bronze alloy applications such as:
Bronze for gears
Large stem valves
Hydraulic cylinder components
907 Tin Bronze
This alloy offers quality corrosion resistance, especially in applications with seawater exposure. This bronze alloy is moderately machinable and performs well in wear and fatigue applications. 907 Tin Bronze is utilized in bronze alloy applications such as:
Bronze for gears
917 Tin Bronze
Typically selected for its increased load carrying capacity – especially heavy loads involving slow and irregular movement – this alloy is highly corrosion resistant and requires adequate lubrication.
917 Tin Bronze is commonly used for applications such as:
Bearings with slow speed and high load
Movable bridge components
Wheels in worm drives
Turntables for bridges
954 Aluminum Bronze
This extremely strong bronze alloy features superior corrosion resistance. It is the most popular aluminum bronze alloy, selected for its exceptional elevated temperature strength, weldability, high tensile and yield strength, as well as ductility. 954 Aluminum Bronze is commonly used in bronze alloy applications such as:
Worms and worm gears (low speed/high strength)
955 Aluminum Bronze
This alloy is among the toughest non-ferrous alloys available. It offers superior yield and compressive strength with high hardness and elongation. 955 Aluminum Bronze offers good corrosion resistance to seawater, as well as impressive heat resistance. It is weldable with good machinability. 955 Aluminum Bronze is found in applications including:
Landing gear components
Bronze for gears
Aircraft engine (seats, valve guides)
Bronze Alloys: Request a Quote
ASI is a leading North American manufacturer of blank gears. With our own bronze foundry and machine shop, we provide end-to-end fabrication services for a wide range of customer needs. We offer quick turnarounds, often delivering in only a week. Customers should note that ASI does not currently cast bronze alloys with high lead content (for example, 928, 932, and 943).