Custom Gears and Sprockets Made Using Wire EDM

If you need a single gear to repair a gearbox and the replacement is no longer available, we can make one from a drawing or a sample. Bas-Agro, a Ukrainian manufacturer of agricultural machinery parts, takes orders for one-off and small-batch production of gear wheels, pinions and sprockets. At our facility in Cherkasy, we use wire electrical discharge machining (wire EDM) to cut complex profiles through the full thickness of a workpiece, including parts made from hardened steel.

Cutting External Teeth and Internal Profiles on the Same Machine

The photo shows a toothed profile being cut on a wire EDM machine. A thin wire acts as an electrode. Electrical discharges between the wire and the workpiece remove tiny amounts of metal. The CNC machine guides the wire along a programmed path, shaping the teeth and the spaces between them.

Video: https://youtube.com/shorts/PgeN5Hze5kw 

The programmed path can follow standard or non-standard profiles. Wire EDM can cut external gear teeth, sprocket profiles, internal gear teeth and through splines. For an external profile, the cut starts at the edge of the workpiece. For a closed internal profile, the wire is threaded through an existing opening or a specially prepared start hole.

Machining Hardened Steel and Making One-Off Parts

Electrical discharges remove metal without the wire making mechanical contact with the workpiece. This allows wire EDM to machine hard, electrically conductive materials, including steel after hardening. We review the drawing to determine whether the specified dimensions and profile can be achieved, taking into account the thickness of the workpiece, the geometry of the part and the required tolerances.

Wire EDM is particularly useful for a single gear or a small batch when the profile would otherwise require a specialised gear-cutting tool. For agricultural machinery repairs, it provides a way to replace an individual component in a gearbox, chain drive or other assembly. We select the manufacturing method for each order based on the profile, material and quantity required.

How to Order Custom Parts from Bas-Agro

We manufacture replacement parts from a drawing or a sample. We can also work from a catalogue number if it provides enough information to identify the part’s specifications. For a quote, send us a drawing or photo of the part, along with the machine model and the quantity you need. Include the steel grade, hardness and tolerances if known. If you have a sample, we’ll agree on which dimensions need to be measured before production.

Bas-Agro phone — +38 (067) 470-35-44

Manufacturing facility — 8/1 Khomenka Lane, Cherkasy, Ukraine

Enquiry form — Bas-Agro contact page

Agricultural machinery parts catalogue — bas.ua

We ship finished parts throughout Ukraine and Europe.