Industrial Helical Worm Gears Manufacturing

Worm wheels are typically produced from CDA 954 aluminum bronze or CDA 932 bronze, with steel available as an alternative. Mating worms are manufactured from carburizing-grade steel, which is then carburized, hardened, and ground to ensure surface durability and long service life under high-torque conditions.

Carnes-Miller Gear achieves AGMA 10 on shaped and hobbed gears, and AGMA 13 on ground spur gears and heat-treated helical gears. These ratings reflect dimensional accuracy, surface finish, and tooth profile precision, making them suitable for demanding aerospace, defense, and industrial drive applications.

Helical gears can be hobbed up to 8 inches in diameter with helix angles up to ±45 degrees, a maximum face length of 300mm, and shaft dimensions up to 100mm diameter by 1,000mm length. For shaping, spur gears can be produced up to 20 inches (500mm) in diameter with a 5-inch face.

Yes. Carnes-Miller Gear offers reverse engineering services for obsolete or damaged worm gears and worms. By providing a physical sample, the team can replicate the gear's geometry, material, and tolerances to produce functionally equivalent replacement parts, minimizing downtime for industrial and mining equipment.

Carnes-Miller Gear serves a broad range of industries including industrial machinery, mining, transportation, construction, agricultural, rail, aerospace, defense, and medical equipment. Their gear manufacturing capabilities support both OEM production runs and aftermarket replacement part requirements across these sectors.

Carnes-Miller Gear offers hobbing, shaping, grinding, and broaching for custom helical and worm gear production. Service options include turn-key manufacturing from blank to finished gear, precision grinding only, and cut-teeth-only services for customer-supplied blanks up to 200mm pitch diameter via hobbing or shaping.