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Case Study: Openex Fabricates Custom Large Gear Segments For Heavy Machinery

Openex, a leading manufacturer of various metal components as well as precision-engineered gears, recently completed a custom fabrication project for a heavy machinery manufacturer. The project involved the production of large gear segments with a diameter of 18000mm, a length of 5000mm, and a width of 250mm. The gear was made of high-strength steel, and it had to be able to withstand the rigors of heavy-duty use.

large gear segments fabrication

Segmental gears, also known as split gears, are used in a variety of applications in heavy machinery. They consist of multiple segments that are bolted together to form a complete gear. This design allows for easier installation and maintenance, as well as greater flexibility in terms of gear diameter.

The production process began with the selection of high-quality steel that was capable of withstanding the rigors of heavy machinery. Once the steel had been selected, it was cut into segments that were 5000mm in length and 250mm in width. These segments were then carefully machined to ensure a precise fit when bolted together.

One of the  challenges faced by Openex during the fabrication process was ensuring that each segment was identical in size and shape. Even small variations in dimensions could result in poor gear performance or failure. To address this issue, Openex utilized advanced computer-aided design (CAD) and computer-aided manufacturing (CAM) software to precisely control the manufacturing process.

Once the individual segments had been machined, they were carefully inspected to ensure that they met Openex's strict quality standards. After all of the segments had been approved, they were bolted together to form a complete gear. The final product was then subjected to a series of rigorous tests to ensure that it was capable of meeting the demanding performance requirements of heavy machinery.

segmetal gear machining

The successful completion of this project highlights Openex's commitment to quality and precision in gear manufacturing. With decades of experience in the industry and a highly skilled team of engineers and technicians, Openex is well-equipped to handle even the most challenging custom fabrication projects.

If you are in need of precision-engineered gears for your machinery or any other metal parts, contact Openex today at to learn more about our services and capabilities.

About Openex

Openex is home to a full-service, one-stop-shop, contract manufacturing company producing custom large machined parts and fabrications. Our full large fabrication services including large machining, cutting, welding, rolling, punching, braking, testing, painting, and others.
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