Printing machinery, large centrifuges, precise machining tools, and industrial equipment are some of the applications for the coarse pitch spur and helical gears that we manufacture. Our CNC hobbing, grinding, and analytical inspection equipment has been specifically selected for the versatility required to produce small lots or long runs of custom gears to standards as demanding as DIN 5 or AGMA Quality 14.

Engineering
Every gear, spline, pulley, or assembly that we manufacture starts as a project for our engineering department. With the aid of high powered CAD/CAM systems, every customer drawing is translated into an INSCO drawing so that our shop will have a consistent format to work to, and to make sure that every stage of manufacture is governed by tolerances and procedures essential to the end product. When our customers require design assistance, we welcome the opportunity to work with their technical staff so that their needs and our know how can be brought together.

Blanking
The quality of a gear is directly related to the quality of the blank from which it is made. That is why we hold tolerances of a few ten thousandths, even on blanks as large as 36 inches in diameter. CNC turning centers, augmented by precision milling, grinding, broaching, and honing capabilities, ensure repeatable accuracy from one blank to the next and facilitate close-tolerance secondary operations. And to make sure that every blank is made of the specified material, each casting, forging, or piece of bar stock is coded at Incoming Inspection with the Shop Order number for which it was purchased.

Hobbing
CNC hobbers serve two purposes: rough hobbing parts to be finish ground, and generating pulleys, splines, worm, spur or helical gears that are hobbed complete to AGMA 10 standards. To ensure the accuracy of these operations, we audit the quality of the hobs we purchase by means of a program developed specifically for our gear analysis systems.

Gear Grinding
The most advanced Reishauer equipment available lets us finish grind spur or helical gears from 48 diametral pitch to 5 pitch. Added to that is a broad array of tooling to eliminate or minimize the cost for many of our customers. Even a single gear can be produced with reasonable economy, while runs of several hundred are characterized by consistent quality as high as AGMA 13/DIN 6. For automotive quality gears and quantities, inquire about our Liebherr gear grinders specifically designed for economical long runs.

Quality Assurance
Quality at INSCO is the responsibility of every machine operator. When a drawing is released by Engineering for manufacture, the first print goes to our chief inspector. It is his responsibility to highlight each dimension, tolerance and call-out to indicate whether 100% inspection, or an appropriate AQL sampling of that characteristic, is necessary. Inspection Travelers then record, by gear serial number, the actual measurements obtained in each operation, thereby assuring documented compliance with the drawing's requirements.

Most of our ground gears are further documented with printouts of our analytical inspection results. Four M&M gear analysis systems compare actual gear tooth parameters to computer models within repeatable accuracy of one micron. Index, involute profile, and lead normally suffice to define the geometrical quality of a gear. However, additional measurements, including tooth thickness, worm lead per convolution, or tooth surface topography, are readily available. If required, the document package that accompanies our shipment can also include heat-treat certification, material analysis, dynamic balance results, "red line" charts of gears inspected with master gears, or other requirements of MIL Standards or similar specifications.

For permanent traceability, our gears can be stamped with part numbers, serial numbers, measurement over wires, and purchase order numbers. Even SPC requirements, when called for, can be accommodated with a program developed for use with our M&M systems.