Custom Gears for Electric Grinder&Cutter | DD Gear

Features & Benefits

• Optimized for high-speed grinding & cutting:
  Designed around the duty cycle of angle grinders, straight grinders and cut-off tools, where the gearbox must handle high-speed rotation, frequent start/stop, intermittent overload and constant exposure to vibration and abrasive dust.

• Spur, helical and bevel gear capability:
  Spur gears are used for efficient, cost-effective internal reduction stages; helical gears provide smoother engagement, lower noise and higher load capacity; straight or spiral bevel gears are applied in 90° angle-head tools to deliver the required output speed and torque at the spindle.

• Compact high-ratio reduction in limited space:
  Multi-stage spur/helical arrangements or bevel combined with spur/helical stages allow high overall reduction ratios in very tight housings, helping tool designers achieve power and ergonomics targets without increasing the external tool size.

• Material and process flexibility:
  Forged and machined alloy steels support heavy-duty, professional tools, while sintered or powder-metallurgy gears can be integrated where near-net-shape, high-volume designs are specified; hybrid or plastic stages can be used in moderate-load, noise-sensitive locations when defined in the customer’s design.

• Small-module precision & noise control:
  Tight control of tooth geometry, contact ratio, runout and surface finish helps achieve low backlash, consistent contact patterns and quieter operation, which is critical for high-speed grinders and cutters in both professional and DIY markets.

• Prototype-to-production support:
  DD Gear can supply early prototype gear sets for new tool platforms, support design refinement based on test feedback, and then stabilize the process for series production under defined control plans and inspection criteria.

Technical Specifications

Final data will be defined according to the customer’s drawing and sample.

Applications

Custom gears for electric grinder & cutter from DD Gear can be tailored to:

• Angle grinders
  Spiral bevel or bevel + helical stages transmitting high-speed motor power to the disc at 90°, with controlled noise and durability.

• Straight grinders and die grinders
  Spur and helical reduction stages between the motor and collet/spindle for burr grinding, deburring and finishing at high rpm.

• Cut-off and cut-off saw tools
  Gear sets that provide the required torque and speed at the cutting wheel, accounting for intermittent overload and shock loading in metal or masonry cutting.

• Tile cutters and small circular saws
  Spur/helical gearboxes for compact, handheld tools that must maintain speed under load while keeping vibration and noise at a manageable level.

• Other electric cutting and grinding tools
  Any small power-tool gearbox requiring custom gears rather than catalog parts, including OEM-specific layouts and ratios.

Gear Manufacturing Process

For grinder and cutter gears, DD Gear typically uses a process sequence tuned to small-module, high-speed and NVH-sensitive applications:

1. Blank preparation – Forged or bar-cut blanks prepared to match the required gear geometry and space envelope.

2. Turning & pre-machining – Machining of bores, diameters and faces, leaving allowance for heat treatment and finishing.

3. Gear cutting – Hobbing or shaping of spur and helical gears; specialized bevel/spiral-bevel gear cutting or multi-axis machining for angle-head gear sets.

4. Heat treatment – Carburizing, carbonitriding, induction hardening or Q&T to reach specified hardness and case depth, while controlling distortion on small gears.

5. Finish machining / grinding – Where required, grinding of bores, journals and tooth flanks to meet runout, accuracy and surface-finish requirements for low noise and long life.

6. Deburring & chamfering – Careful removal of burrs and sharp edges on gear teeth to limit stress concentrations and reduce noise in high-speed operation.

7. Cleaning, corrosion protection & packaging – Cleaning and protective measures according to the customer’s assembly and logistics requirements.

If your design specifies sintered or hybrid gears, DD Gear can integrate with your chosen PM/hybrid supply chain and provide finishing and inspection services as part of the complete gear solution, subject to project discussion.

Precision Gear Customization Process

To support custom electric grinder & cutter gear projects, DD Gear follows a clear, eight-step customization process:

Step 1 – Requirement Collection
Customers provide design requirements, 2D drawings, 3D models, or physical samples, together with basic duty cycle information (torque, speed, life, installation).

Step 2 – Drawing Design & Optimization
Based on the provided drawings or samples, DD Gear prepares or optimizes detailed manufacturing drawings and shares them with the customer for confirmation.

Step 3 – Quotation
After the drawings and technical points are confirmed, we issue a precise quotation covering tooling, piece price, lead time, and quality requirements.

Step 4 – Tooling & Fixture Preparation
Once the price is confirmed, we arrange tooling and fixture production. Any tooling cost is agreed with the customer in advance and can be offset or refunded after mass orders, according to the commercial agreement.

Step 5 – First Sample Approval
After tooling and fixtures are ready, we manufacture the first sample batch—typically within about 30 days—and ship it to the customer for testing.The customer inspects and validates the samples in their gearbox or test bench and provides feedback on dimensions, performance, and any required adjustments.

Step 6 – Mass Production
When the sample is approved, we start mass production according to the agreed production plan and quality standards.

Step 7 – Finished Product Inspection
After production, we inspect hardness, dimensions, runout, tooth accuracy, and other critical characteristics to ensure full compliance with the drawing and standards.

Step 8 – Shipping Arrangement
Once inspection is passed and shipment is approved by the customer, we arrange booking, packaging, and delivery to the specified destination.

Quality Assurance & Inspection

DD Gear applies the same quality philosophy to electric grinder & cutter gear and all precision gears:

• Quality management systems based on ISO 9001 and IATF 16949

• Process control from incoming material to final inspection, including:

  • Material certification and chemical composition checks

  • Hardness and case depth verification after heat treatment

  • Gear measurement for profile, lead, pitch, and runout

  • Surface roughness testing on gear flanks and journals

  • Dimensional inspection with calibrated gauges and CMMs

• Traceability for each batch with inspection records and reports

• Optional documentation such as PPAP/FAIR packs on request

Packaging

Usage & Installation Notes

• Keep shaft alignment and bearing fits within drawing tolerances; small deviations can significantly affect mesh quality, noise and wear in high-speed, small-module gearboxes.

• Use the specified lubricant type and filling method (grease, oil-splash, etc.), as incorrect lubricants or fill levels can increase noise, temperature and tooth wear.

• Avoid mixing gears from different sets unless they are explicitly designed to be interchangeable; even small geometry differences can influence noise in sensitive power-tool gearboxes.

• During testing and field monitoring, track noise, vibration and temperature trends; any abnormal rise is a signal to inspect tooth contact, lubrication and bearing condition before serious damage occurs.

Company Strength – DD Gear

• Specialized in small module, high-precision gears and shafts for EVs, humanoid robots, AGVs, and intelligent automation.

• Integrated manufacturing from forging and machining to heat treatment and gear grinding.

• Quality systems aligned with automotive standards, with experience supporting OEM and Tier 1 projects.

• Engineering support covering concept feasibility, DFM reviews, and failure analysis feedback.

• Global export capability with experience serving customers in multiple countries.

Q1: What information do you need to quote gears for an electric grinder or cutter?
We normally need the gearbox layout and gear drawings/3D models, material and heat-treatment requirements, torque and speed ranges, duty cycle (continuous/intermittent, typical load vs. maximum load), target noise level, expected service life and annual volume.

Q2: Should we use spur or helical gears in our grinder or cutter gearbox?
Spur gears are simpler and cost-effective, suitable for internal reduction stages where noise is not the dominant constraint. Helical gears provide smoother engagement, higher contact ratio and generally lower noise and vibration, which is valuable in professional tools or high-speed stages—but they also generate axial thrust that must be managed in the bearing design.

Q3: Do you supply complete gearboxes or only gears?
DD Gear is a component supplier. We provide gears and related parts based on your drawings. Complete grinder/cutter gearboxes and finished tools are designed and assembled by the power-tool OEM or system integrator.

Q4: Can you support noise reduction and durability improvements?
We can review tooth geometry, material and heat treatment from a manufacturability and performance perspective, and work with your engineering team to adjust contact ratios, tooth modifications and surface treatment to help balance noise, durability and cost. Final NVH and life validation must be performed in your complete gearboxes and tools.

Q5: Can you work with powder-metallurgy or hybrid gear designs?
Yes—if your design specifies sintered or hybrid gears, we can cooperate with qualified PM/hybrid suppliers or work with your existing supply chain to provide finishing, inspection and relevant support, subject to project scope and agreement.