Company Overview

KAI HE MACHINERY CO., LTD specializes in manufacturing high-quality gear racks using advanced equipment such as rack teeth rollers, MCV vertical machine centers, and rack grinding machines. The company prioritizes professionalism and quality service to deliver cost-effective, precise products. Melucci S.r.l. in Rimini, Italy, acts as a distributor or partner, providing contact details for customer support.

Rack Product Specifications and Coding

Racks are identified by a comprehensive order code that specifies quality grade (DIN 5 to DIN 10), length (500 mm to 2000 mm), module size (M2 to M10), heat treatment type (H for heat treated, Q for quenched), machining process (F for precision milling, G for grinding), tooth type (straight or helical), and material (S45C or SCM440). This coding ensures precise product identification and ordering.

Assembly Procedures

1. Secure the pin into the side hole of the rack.
2. Install racks A and B onto the base, ensuring alignment of installation holes.
3. Use a reverse gauge to verify correct pitch between racks; consult technical staff if abnormal pitch is detected.

Proper alignment of rack and pinion pitch lines is critical. Applying a red compound helps check gear mesh contact patterns under load, ensuring optimal engagement.

Quality and Tolerances

Quality grades range from DIN 5 to DIN 10, each with defined tolerances for total pitch error and single pitch error measured in micrometers. Tooth thickness tolerances vary by module and quality grade, typically between -124 to -15 micrometers. Examples include total pitch error limits of ≤0.036 mm for 1000 mm length at DIN 6 quality.

Materials and Heat Treatments

Materials used include C45E (SSGH series) and 42CrMn4 (RSGH series). Heat treatments include induction hardening and quenching, with hardness levels typically between 15° and 55° HRC depending on quality grade. Surface treatments involve grinding or milling of sides and teeth. Pressure angles are approximately 20°, with helical angles ranging from 15° to 55° depending on rack series.

Load and Performance Data

Load tables specify normal force (FN) and torque (TN) values for various modules and tooth counts. For instance, the SHGH series torque ranges from about 3,178 Nm for smaller modules to over 175,000 Nm for larger modules. Similar performance data is provided for SSGH, SHF/SSF, SSFQ/RSFQ, and SSFH/RSFH series, indicating expected mechanical capabilities under load.

Measurement Methods

Tooth thickness is measured indirectly using a measuring pin inserted into the teeth, as direct measurement is not feasible. This method ensures verification of tooth thickness within specified tolerances.

Summary of Key Parameters

• Rack lengths: 500 mm to 2000 mm
• Modules: M2 to M10
• Quality grades: DIN 5 to DIN 10
• Heat treatments: Induction hardened, quenched, or untreated
• Materials: C45E, 42CrMn4, S45C, SCM440
• Surface treatments: Ground or milled
• Pressure angle: Approximately 20°
• Helical angle: 15° to 55° depending on series
• Pitch error tolerances vary by length and quality grade
• Load capacities detailed per series and module

Recommendations and Best Practices

• Follow correct assembly sequence and ensure precise alignment to maintain pitch accuracy.
• Use reverse gauges and red compound checks to verify pitch and gear mesh quality.
• Consult technical staff if abnormal pitch or tooth conditions are observed.
• Adhere to specified tolerances and quality grades to ensure optimal performance and longevity.

Technical Summary of Gear Rack Specifications and Standards

1. Overview

The document details technical specifications, quality standards, and manufacturing treatments for gear racks compliant with DIN standards, covering dimensions, materials, heat treatments, surface treatments, hardness, pitch errors, and order codes.

2. Gear Rack Series and Quality Grades

• SSF Series – DIN 9 (Q9)
• SHGH / RHGH Series – DIN 6 (Q6) and DIN 5 (Q5)
• SHFQ / RHFQ Series – DIN 8 (Q8)
• SHFH / RHFH Series – DIN 7 (Q7)
• SHF Series – DIN 9 (Q9)

3. Material and Heat Treatment

• Materials: C45E (SHGH, SHFQ, SHFH, SHF), 42CrMn4 (RHGH, RHFQ, RHFH)
• Heat Treatments: Induction hardened (SHGH, RHGH, SHFH, RHFH), quenched (SHFQ, RHFQ), untreated (SHF)

4. Surface and Teeth Treatments

• Sides are ground or milled depending on series.
• Teeth are ground or milled with pressure angles of 20° and helical angles of approximately 19° 31' 42".
• Hardness ranges from 15° to 55° HRC, with specific DIN hardness grades per series.

5. Quality and Pitch Error Specifications

• Defined maximum total pitch errors (Gtf) over lengths of 1000 mm, 1500 mm, and 2000 mm vary by quality grade, e.g., Q9 (SSF) ≤ 0.036 mm/1000 mm, Q6 (SHGH/RHGH) ≤ 0.026 mm/1000 mm, Q5 (SHGH/RHGH) ≤ 0.100 mm/1000 mm.

6. Dimensional and Ordering Data

Includes detailed millimeter dimensions, order codes, hole counts, module sizes, and pitch parameters essential for precise ordering and manufacturing control.

7. Manufacturer Information

Melucci S.r.l.
Via Emilia, 78-80, 47921 Rimini (RN), Italy
Tel: +39 0541 775768
Fax: +39 0541 773011
Email: [email protected]
Website: www.melucci.it

Critical Notes and Best Practices

• Select quality grades based on required pitch error tolerances.
• Match material and heat treatment to application needs for hardness and durability.
• Choose surface and teeth treatments to optimize gear performance.
• Verify order codes and dimensions carefully to ensure DIN standard compliance.

This summary consolidates the essential technical specifications, quality standards, and manufacturing guidelines for various gear rack series as presented in the document.