Zinc Die-Cast Bevel Gears Straight-Tooth System Ratio 1:1

Zinc die-cast bevel gears with a straight-tooth system and a 1:1 ratio are mechanical components designed to transmit power and motion between two intersecting shafts at a 90° angle. Made from zinc alloy (typically ZnAl4Cu1), these gears feature straight teeth with a 20° engagement angle, offering efficient torque transfer for applications requiring equal speed and power between shafts. They are cast with machined bores for precise fitting and have a bright, zinc-plated or varnished finish for corrosion resistance.

Suitable for light to moderate loads, they operate reliably up to 100°C but are less ideal for continuous heavy-duty use due to material limitations. The 1:1 ratio ensures identical tooth counts on mating gears, maintaining consistent rotational speed. These gears are sold individually, requiring two matching gears for a pair.

Zinc Die-Cast Bevel Gear Ratio 1:1

• In the torque calculation of zinc-die-cast bevel gears only the root strength was considered.
• Due to the material properties these gears are only to a limited extend suitable for continuous operation.

Advantages of Zinc Die-Cast Bevel Gears

1. Cost-Effective Production: Zinc die-casting allows for high-volume manufacturing with low material and processing costs. The process creates precise, complex shapes without extensive machining, making these bevel gears an economical choice for applications requiring reliable performance on a budget, such as in small machinery or consumer products.
2. Corrosion Resistance: The zinc alloy composition, often coated with a bright zinc-plated or varnished finish, provides excellent resistance to corrosion. This makes the bevel gear sets suitable for environments with moderate exposure to moisture or chemicals, extending their lifespan in light industrial or outdoor applications.
3. High Dimensional Accuracy: Die-casting ensures tight tolerances and consistent tooth profiles, resulting in smooth and efficient power transmission. The machined bores enhance fitment precision, reducing misalignment and wear, which is critical for maintaining performance in 90° shaft angle applications.
4. Lightweight Design: Zinc alloys are lighter than steel or brass, reducing the overall weight of assemblies. This is advantageous in applications like portable devices or small machinery, where minimizing weight improves efficiency and ease of handling without sacrificing structural integrity.
5. Good Strength for Light Loads: While not as robust as steel, zinc die-cast bevel gears offer sufficient strength for low to moderate torque applications. Their 1:1 ratio ensures balanced speed and power transfer, making them ideal for small motors or hand-driven mechanisms.
6. Ease of Customization: The die-casting process allows for flexible design modifications, such as custom bore sizes or tooth configurations, to meet specific application needs. This adaptability supports rapid prototyping and tailored solutions for niche mechanical systems, enhancing design versatility.

Applications of Zinc Die-Cast Bevel Gears

1. Small Appliances and Household Equipment: Zinc die-cast bevel gears are commonly used in compact household appliances like blenders, mixers, and fans. Their lightweight nature and excellent wear resistance ensure smooth and efficient operation while minimizing noise and requiring little maintenance over time.
2. Robotics and Automation Systems: These gears are ideal for robotics and automation due to their high dimensional accuracy and lightweight design. They ensure precise motion control and torque transfer in robotic joints and actuators, enhancing the efficiency and reliability of automated systems.
3. Automotive Components: Zinc die-cast bevel gears are used in automotive applications such as power seat adjusters, mirror actuators, and small electric motor systems. Their corrosion resistance and durability make them suitable for long-term use in vehicles under varying environmental conditions.
4. Industrial Machinery: In light-duty industrial machinery, these gears facilitate motion transfer between shafts in applications like conveyor systems, packaging machines, and small tooling equipment. Their ability to handle moderate torque ensures reliability and consistent performance in such operations.
5. Medical Devices: The precision and compactness of zinc die-cast bevel gears make them suitable for medical devices like imaging equipment, surgical tools, and diagnostic machinery. Their smooth operation and reliability are critical in applications that require accuracy and consistency.
6. Office Equipment and Printers: Zinc die-cast bevel gears are used in office equipment such as printers, copiers, and shredders. Their precise motion control and quiet operation ensure efficiency and reliability in devices designed for frequent use in professional environments.

Robotics and Automation	Automotive Industry
Industrial Machinery	Printers