From steel to aluminium gears
For this challenge, Case New Holland turned to RG Castings Group. The solution: replace steel gears with aluminium versions. Simple in theory, but delivering a full prototype series was far more challenging. From project initiation to finished gears ready for intensive endurance testing, RG Castings completed the task in just five weeks. High-load gears demand a well-thought-out design, a robust alloy, and flawless finishing.
A challenge perfectly suited to our expertise
When other suppliers dropped out, RG Castings proved its worth as a flexible, technically skilled development partner. We produced five different aluminium cast components, each as a batch of five prototypes. To speed and precision in manufacturing, we engineered specific proto-sand molds for each gear. One of the most demanding castings measured 450 mm in diameter and weighed 14.7 kg.
After casting, a meticulous machining process followed: T6 heat treatment for optimal hardness, CNC machining for precision, and balancing for vibration-free operation. Finally, the tooth profiles were hard-anodized for maximum wear resistance and long-lasting corrosion protection.
Field testing paves the way for the future
The aluminium gears are currently undergoing intensive endurance tests in Ireland. Installed in Case New Holland test machines, they are being evaluated under realistic field conditions. Their performance will be decisive: if they prove themselves, aluminium will take a structural role in the drivetrains of future maize harvesters.
