(574) 234-4116 
Manufacturing in Roscoe, Illinois
Schafer Gear Works-Roscoe, Illinois specializes in manufacturing large, high-precision gears with gear grinding to AGMA Class 13 up to 32" in diameter and face shaping to 8.5". When you work with our team, you’ll get gears made to your exact specifications so you’re ready to deliver the product quality your aerospace, agricultural, construction, mining, machine tool, oil and gas or transportation market demands.
Capabilities
No other manufacturer is better staffed and equipped to manufacture your large gears than our Schafer Gear Works-Roscoe, Illinois facility. We take pride in our gear grinding capabilities from 0.5" to 32" diameter and our special ability to do internal gear grinding from 0.5" to 36" diameter.
See us to meet your dimensions and quality standards for:
- Spur Gears
- Helical Gears
- Planet Gears
- Ring Gears
- Sun Gears
- Pump Gears
- High Contact Ratio Gears and Worms (HCR Gears)
- Parallel Axis Gears
And if our current capabilities do not meet your needs, let’s talk. We continually expand and adapt our processes as our customers’ needs change.
Equipment
Gear Grinding (Spur & Helical)
- 1 - Gleason TAG-400 CNC (15.75") 8-axis Gear Grinder
- 1 - Höfler Rapid 1500 1.5M CNC Gear Grinder (recent acquisition)
- 1 - Höfler Model 800 CNC Single Tooth Gear Grinder, 31" x 60" Long with internal grinding capabilities; NEW in 2012
- 1 - Höfler Model 700 CNC Single Tooth Gear Grinder, 27.5" x 54" Long, Equipped to straight, crown, and taper grind. We can also CBN Grind Gears.
- 1 - Höfler Model 400 CNC Single Tooth Gear Grinder, 16" x 36"
- 1 - Niles ZE800S (32") Gear Grinder
- 1 - Reishauer Model RZ 1000 CNC Gear Grinder, 40” Dia. Maximum, Designed for Production Work
- 1 - Reishauer Model RZ 400 CNC Gear Grinder, 16" Dia. Maximum, Designed for Production Work; NEW in 2008
- 1 - Reishauer Model RZ 301 AS CNC Gear Grinder, Equipped to Straight, Crown, and Taper Grind, 13" Dia. Maximum
- 1 - Reishauer Model 300E Gear Grinder , Equipped to Straight, Crown, and Taper Grind, 13" Dia. Maximum
Gear Hobbing
- 3 - Barber Colman Machines (up to 16-56)
- 1 - Barber Colman 16-56, Horizontal Hobbing Machine, 16" x 56" Long
- 1 - Barber Colman 16-10, Vertical Hobbing Machine, 16" x 10v Long
- 3 - Barber Colman 16-36, Horizontal Hobbing Machine, 16" Dia. x 36" Long
- 1 - Barber Colman 16-16, Horizontal Hobbing Machine, 16" Dia. x 16" Long
- 1 - Barber Colman 25-15, Vertical Hobbing Machine, 25" Dia. x 15" Face Maximum
- 1 - Barber Colman 40-15, Vertical Hobbing Machine, 40" Dia. x 15" Face Maximum
- 1 - Barber Colman 10-12, Vertical Hobbing Machine, 10" x 12" Long
- 1 - Barber Colman 10-12, Hob Sharpener, 10" Dia. x 12" Long
- 1 - Bourn & Koch , 200 CNC Horizontal Gear Hobbing Machine, 8" Dia. x 44" Long
- 1 - Bourn & Koch, 100 CNC Horizontal Gear Hobbing Machine, 6" Dia. x 30" Long
- 1 - Chongqing CNC (31.5")
- 3 - Chongqing Model YKB3180, Vertical Hobbing Machine, 800 mm Dia. Maximum
- 3 - Chongqing Model YB3150E, Vertical Hobbing Machine, 500 mm Dia. Maximum
- 2 - Fellows/Pfauter P900 (35")
- 1 - Höfler HF 650 800MM CNC Gear Hobber (recent acquisition)
- 1 - Hurth Model WF500, CNC Gear Hobbing Machine, 25" Dia. Maximum
- 1 - Leibherr 652 (25.5") CNC
- 1 - Liebherr Model 652, Vertical Hobbing Machine, Equipped to Crown and Taper Hob, 27" Dia.
- 2 - Liebherr Model 255, Vertical Hobbing Machine, 10" Dia. x 8" Long
- 1 - Liebherr Model 252, Vertical Hobbing Machine, 10" Dia. Maximum
- 1 - Mitsubishi GC40 16" 5-Axis
- 1 - Mitsubishi GD20 8" 5-Axis
- 1 - Pfauter P-630 (25")
- 1 - Pfauter Model P630 , Vertical Hobbing Machine, 26" Dia. Maximum
- In-house cutter sharpening
Gear Shaping & Shaving
- 1 - Barber Colman Type 10-4 Machine (10")
- 1 - Barber Colman 18-4, Gear Shaper, 18"Maximum O.D. or I.D. by 4" Face Width
- 1 - Bourn & Koch/Fellows 36-8, CNC Gear Shaper, 36" Maximum O.D. or I.D. by 8" Face
- 3 - Fellows Model 36, Gear Shaper, 36" Maximum O.D. or I.D. by 6" Face Width
- 3 - Fellows 36-6 Machines
- 1 - Fellows 10-4, Gear Shaper, 10" Maximum O.D. or I.D. by 4" Face Width
- 1 - Fellows Model 645A, Gear Shaper, 18" x 6"
- 1 - National Red Ring GCI 12, Gear Shaver, Equipped with Crowning Attachment, 12" Dia.
- 1 - National Red Ring (12")
- 1 - National Red Ring (16")
- 1 - National Red Ring GCI 18, Gear Shaver, Equipped with Crowning Attachment, 18" Dia.
- In-house cutter sharpening
Turning Centers
- 1 - Femco HL 55 2-Axis Lathe
- 1 - Haas CNC Lathe, 25.5" Dia. x 44" Long; NEW in 2014
- 1 - Haas CNC Lathe, 21" Dia. x 26" Long; NEW in 2014
- 1 - Ikegai TT25 CNC 4 Axis Slantbed Lathe , 13-1/4" Dia. x 28" Long
- 1 - Johnford ST 60 CNC Turning Center
- 1 - Mazak Integrex 30 CNC Turning/Milling Center
- 1 - Mori Seiki CL2000 CNC Lathe
- 1 - Mori Seiki NL3000 CNC Lathe
- 1 - Mori Seiki NL2500 CNC Lathe
- 2 - Okuma Howa CNC V80R Turning Machines (recent acquisition)
- 1 - Romi G50 CNC Turning Center
- 1 - Summitt Engine Lathe, 16" Dia. x 72" Long
- 1 - Warner & Swasey 4A Turret Lathe, 29" Dia. x 60" Long
- 1 - Warner and Swasey #2A Turret Lathe
- 1 - Warner and Swasey #1A Turret Lathe
Sawing
- 1 - DoAll Vertical Bandsaw
- 1 - Peerless Spartan PA 13/2 Band Saw (13")
- 1 - Spartan Horizontal Cutter Saw, 10" Dia. Maximum
- 1 - Spartan PA 13/2, Horizontal Cutoff Saw, 13" Dia. Maximum
- 1 - Spartan PA 18/3 , Horizontal Cutoff Saw, 18" Dia. Maximum
Broaching
- 1 - American Vertical Broach, 50 ton 60" Maximum Length
- 1 - Broaching Machine Specialties Horizontal Broach 100" 35 Ton
Grinding
- 1 - ACRA-ASG 20"x40" Surface Grinder
- 1 - Carl Citron G-12-40 Universal O.D. & I.D. Grinder, 10" x 48" Long
- 2 - Cincinnati Milicron I.D. Grinders
- 1 - Excello 274 Center Grinder, 3" Dia.
- 3 - Heald 272 Internal Grinders, 20" Dia.
- 1 - Heald 361 Rotary Surface Grinder, 24" Dia.
- 1 - K.O. Lee C660L2 O.D & I.D Grinder, 26" x 14"; NEW in 2014
- 1 - Okamoto Surface Grinder
- 1 - Okamoto IGM-3U O.D & I.D. Grinder, 27.7 x 20" Added in 2014
- 1 - Taisei Universal CNC ID/OD Grinder 31.5"
- 1 - Toyoda Select G (CNC) OD Grinder
- 1 - Toyoda Cylinder Grinder
Drilling/Milling
- 1 - Bridgeport Model J Vertical Milling Machine
- 1 - Fadal VMC 4020, Vertical Machining Center equipped with 4-Axis 20" x 40"
- 2 - HAAS UF-3SS 4 Axis Superspeed Vertical Machining Center, 20" x 40" x 25" Travel
- 1 - HAAS 3VF, 4 Axis Vertical Machining Center - 20" x 40" x 25" Travel
- 1 - HAAS EC1600, 4 Axis Horizontal Machining Center - 64" x 40" x 40" Travel
- 1 - Micro Cut Model 5000, VS Vertical Machining Center - 16" Dia.
- 1 - Micro Cut Model 1050, Vertical Machining Center - 14" Dia.
- 1 - Kent KTM-5VK Vertical Milling Machine
- 1 - Lagun FTV-25 Vertical Milling Machine
- 1 - Okuma & Howa Millac 6VA CNC Vertical Machining
- 1 - Yama Seiki Super BM-1600 Vertical Machining Center (recent acquisition)
Finishing
- 1 - Cross Model 55, Tooth Rounding and Pointing Machine, 18" Dia. Max.
- 1 - Chamfermatic, Gear Deburring Machine, 24" Dia.
- 2 - Redin, Gear Deburring Machine, 20" Dia.
Inspection/Quality Assurance
- 1 - Brown & Sharpe CMM Unit
- 2 - Brown & Sharpe Micro-Hite (30") Gages
- 1 - Brown & Sharpe Co-Ordinate Measuring Machine; NEW Zeiss CMM Coming 2014
- 2 - Brown & Sharpe 30” Electronic Height Gauge, 30" Dia. Maximum
- 1 - Dip Seal Tank
- 1 - Gleason 1000 GMM Gear Inspection System (recent acquisition)
- 1 - Klingelnberg P-100 Gear Inspection Machine, 40" Dia. Maximum; NEW in 2013
- 1 - Klingelnberg P-40 CNC Gear Inspection Machine,16" Dia. Maximum
- 1 - Klingelnberg P-100 Gear Inspection Machine, 40" Dia. Maximum; NEW in 2013
- 1 - Klingelnberg P-40 CNC Gear Inspection Machine, 16" Dia. Maximum
- 1 - Magnaflux Magnetic Particle Inspection Unit
- 1 - Magnaflux Machine
- 1 - Mitutoyo PH-3500 (16") Optical Comparator
- 1 - Nital Etch
- 1 - Profilometer
- 1 - Rockwell Hardness Tester
- 1 - Stylinea Mark IV, CNC Marking Machine
- 1 - Wenzel XO 107 1.5M X 1.0M CMM (recent acquisition)
Specifications
| Gear Hobbing and Shaping Capabilities | ||
| Minimum | Maximum | |
| Outside Diameter | 0.5" (13 mm) | 32" (813 mm) |
| Hobbing | Shaping | |
| Maximum Face Width | 50" (1,270 mm) | 8.5" (216 mm) |
| Maximum Helix Angle | 45° | 36° |
| NDP | Module | |
| Diametral Pitch Range | 1.5 to 36 | 17 to .75 |
| Quality Level Maximum | 10 AGMA 2000-A88 | |
| Gear Grinding Capabilities | ||
| Minimum | Maximum | |
| Outside Diameter | 0.5" (13 mm) | 36" (914 mm) |
| Maximum Face Width | 39.4" (1,000 mm) | |
| Maximum Part Length | 59" (1,500mm) | |
| Maximum Helix Angle | 45° | |
| NDP | Module | |
| Diametral Pitch Range | 1.0 to 25.4 | 25.4 to .1.0 |
| Maximum Grinding Wheel Diameter | 2.250" (57.2mm) | |
| Quality Level Maximum | 15 AGMA 2000-A88 | |
Internal Spur and Helical Gears
| Shaping Capabilities | ||
| Minimum | Maximum | |
| Inside Diameter | 0.5" (13 mm) | 36" (914 mm) |
| Spur | Helical | |
| Maximum Face Width | 8.5" (216 mm) | 4.72" (120 mm) |
| Maximum Helix Angle | 36° | |
| NDP | Module | |
| Diametral Pitch Range | 1.5 to 36 | 17 to 1.5 |
| Quality Level Maximum | 11 AGMA 2000-A88 | |
| Gear Grinding Capabilities | ||
| Minimum | Maximum | |
| Inside Diameter | 2.3" (59 mm) | 36" (914 mm) |
| Maximum Face Width | 7.87" (200 mm) | |
| Maximum Part Length | 59" (1,500mm) | |
| Maximum Helix Angle | 15° | |
| NDP | Module | |
| Diametral Pitch Range | 3.0 to 25.4 | 8.5 to 1.0 |
| Minimum Grinding Wheel Diameter | 2.30" (58.4mm) | |
| Quality Level Maximum | 14 AGMA 2000-A88 | |
| Ground Spur and Helical Gear | |
| Diameter: | 1" to 60" |
| Pitch: | 3 to 24 DP AGMA Class 13 |
| Spur and Helical Hob | |
| Diameter: | 1" to 36" |
| Pitch: | 3 to 32 DP |
| Spur and Helical Shape | |
| Diameter: | 1" to 36" |
| Pitch: | 3 to 32 DP 6" Face Width |
| Ground Worm | |
| Diameter: | None |
| Pitch: | |
| Worm Gear | |
| Diameter: | None |
| Pitch: | |
| Bevel Gear | |
| Straight | |
| Diameter: | None |
| Pitch: | |
| Spiral | |
| Diameter: | None |
| Pitch: | |
| Broached Spline | |
| Diameter: | Up to 4" |
