Innovative & Cutting-edge Technology

During the production process, the company has developed these core technologies.

Thin-Walled Hollow High-Speed Motor Shaft

Features

Lightweight design with long hollow bores and thin walls to meet weight reduction requirements.

Process advantages
  • Deep Hole Machining: Includes tools, equipment, processes, and cooling techniques for deep hole drilling
  • Heat Treatment of Hollow Thin-Walled Products: Involves specialized fixtures and processes for heat treating these products
  • External Grinding Technology for Ultra-Long Thin-Walled Hollow Shafts: Utilizes advanced grinding wheels, dressing processes, and grinding techniques.
  • Fully Automated Full-Size Online Testing: Self-developed automated testing equipment that can comprehensively measure key dimensions such as tooth profiles, outer diameter, length, runout, and roundness.

The rotary forging process for integrated motor

shafts

Features

Integrated design of the input shaft, while retaining the hollow design of the motor shaft, integrated design can compress the size, reduce the number of parts, improve accuracy, lightweight and other advantages, as shown in picture.

Process advantages

Rotary forging forming technology. Rotary forging forming technology referred to as rotary forging, is a kind of rotary progressive near-net forming process, rotary forging has the advantages of small load, forming chipless, high strength after forming, high productivity, low die cost, etc., and at the same time, it is conducive to improving the material usage rate, reducing energy consumption, and realizing the lightweighting of the parts and so on. In order to be able to ensure these key requirements, spin forging equipment to achieve the accuracy of the clockwork device. Spin forging process forming process fast and better surface quality, compared with traditional cutting methods, high degree of automation and wide range of processing.

The differential and main reduction gear integrated and utilize laser welding technology.

Features

Whether in traditional passenger cars or new energy passenger cars, the differential is an important component of automotive parts. It provides power transmission and ensures safe differential when the car turns. Traditionally, the differential and the main reduction gear are connected physically, i.e., using bolts, which requires a high torque for the bolts due to the characteristics of the differential. By using a laser welding integrated production system, the main reduction gear and the differential are chemically fused and welded into a single unit. This approach can save the costs of numerous expensive bolt connections and significantly reduce the weight.

Process advantages
  • Surface Cleaning Before Welding: The surfaces of the welding areas on the differential housing and the main reduction gear are laser-scorched to remove all residues, such as coolants or preservatives, reducing impurities’ impact on the welding quality. In laser cleaning, the laser power is kept low to achieve cleaning without damaging the product.
  • Welding Fixture: Ensures the relative position and welding precision between the differential housing and the main reduction gear during the welding process.
  • Optimal Welding Parameters: Achieves minimal welding deformation, minimal welding spatter, high welding quality, and prevents false welding.

High-speed input shaft (hard drawing process)

Features

Lightweight design with long hollow bores and thin walls to meet weight reduction requirements.

Process advantages

Hard broaching is employed to process high-hardness workpieces, utilizing ultra-fine carbide and coatings that are more heat-resistant and wear-resistant. The process is performed on a high-speed, high-rigidity hard broaching machine with a cutting speed of up to 60 meters per minute. This allows for complete removal of deformations caused by heat treatment, achieving the desired involute shape and high-precision hole shape. The actual processing time is just one second, making this method more energy-efficient and environmentally friendly.

High-precision DCT transmission shaft (powerful skiving, rolling, fine polishing)

Process advantages
  • Adopting the powerful internal gear honing process addresses issues related to dressing wheels, grinding wheels, grinding wheel dressing, and honing processes. The processed workpiece gears achieve high precision, and the “herringbone” pattern formed on the gear surface effectively reduces noise during gear transmission.
  • The forming mechanism and key parameters of the involute spline rolling process were analyzed. Based on the tooth profile changes during the stages of biting, rough rolling, fine rolling, and withdrawal, the metal flow characteristics in the plastic forming process were studied, leading to optimized processing parameters.
  • For the high-precision roughness requirements at the bearing end, belt polishing is employed. During polishing, elastic deformation occurs between the contact wheel, the abrasive belt, and the workpiece, resulting in good vibration resistance for the entire system. This method offers high production efficiency, superior surface quality, and low production costs.

Integrated secondary shaft assembly (powerful skiving, compound external grinding)

Process advantages
  • The powerful internal gear honing process addresses issues related to dressing wheels, grinding wheels, grinding wheel dressing, and honing processes. The processed workpiece gears achieve high precision, and the “herringbone” pattern formed on the gear surface effectively reduces noise during gear transmission.
  • The compound grinding process employs a dual-spindle grinding solution, using custom grinding wheels and a special dressing process. This allows for the completion of grinding in a single clamping operation.

Steering Worm (Milling and Grinding)

Features

Due to meshing with plastic gears, the worm has very high precision requirements and needs a tooth surface roughness of less than Ra0.3. Worm grinding alone cannot fully meet these demands.

Process advantages
  • The process involves precision grinding after tooth surface milling, followed by burnishing to ensure the tooth surface roughness is less than Ra0.3. Given that the workpiece material is processed in a tempered state, the difficulty increases. Specialized milling cutters and grinding wheels were developed to balance the relationship between milling and grinding. The finishing allowance is precisely controlled, and a precision burnishing wheel is used for fine finishing. This ensures the tooth surface roughness meets requirements without compromising the accuracy and tooth profile modification.
  • The gear teeth require even higher precision for the involute profile, with special modification areas at the tooth tip and root, ensuring the rounded corners at the tooth tip meet the requirements.

Processing Equipment

XIASHA Precision is continuously investing in equipment towards a specialized direction of “high, precise, specialized, and unique”. While introducing advanced equipment and technology, the company emphasizes learning and innovation, striving to develop its own core technologies.

The company already possesses a sizable array of high-precision gear hobbing machines, gear grinding machines, gear honing machines, gear shaping machines, and gear broaching machines.

Gear Grinding Machine
REISHAUER-RZ 126 4.0
Gear Grinding Machine
Liebherr-LGG280
Gear Honing Machine
PRÄWEMA-205H
Gear Skiving Machine
Liebherr-lk-180
Hobbing Machine
2Gleason-60HMS
Cylindrical grinding machines
junker-Lean Selection speed

Testing Equipment

The company rigorously implements a quality control system, continuously optimizing its quality control processes to enhance its capabilities. It has established and implemented a high-standard quality management system according to ISO9001 and IATF16949 standards, becoming one of the key factors for entering and maintaining stable relationships with international well-known enterprise groups’ supply chains.

The company equips its quality inspection stages with advanced testing equipment through external purchases, such as Mahr contour measuring devices, Klingelnberg gear testers, and Zeiss coordinate measuring machines, ensuring the precision, reliability, and consistency of its products.

The company’s high standards in product quality and quality control systems are crucial for acquiring new customers and establishing long-term stable business relationships.

Coordinate Measuring Machine
Zeiss-CMM
Contourgraph
Mahr-MMQ 400-2
Optical Shaft Measuring Technology
Jenoptik-CS608 Pro
Fourier measurement device
OPTOSHAFT
Single head single mesh analysis system
INTRA-M19320
Gear Decector
Gleason-300gms
Gear Decector
Klingelnberg-P40
Gear Decector
REISHAUER-RZ 126 4.0

Team Technical Breakthrough

The team uses Romax, Simpack, and Ansys simulation software to validate transmission efficiency, durability, and NVH (Noise, Vibration, and Harshness) characteristics.

  • Through simulation, the design theoretical calculation values can be compared with the actual simulation results in the most intuitive way (reliability 70-80%);
  • By simulating strength, the overall structure of the gearbox can be optimized;
  • By simulating gear meshing, the design of the parts can be optimized.

Romax

Simpack

Ansys