Gear Cutting 101 - Newmac Equipment

19-06-2026

Gear Cutting 101

Hobbing, Shaping, and Milling Explained

Gears are everywhere in engineering — but how they’re actually cut is something most people outside the trade never think about. There are three main methods, each with its own machine type, history, and sweet spot.

Gear Hobbing — The Production Workhorse

Hobbing uses a rotating multi-tooth cutting tool called a hob, which feeds across a rotating gear blank. Both the hob and the blank rotate in a synchronised ratio — the result is a continuous, efficient cut that generates the tooth profile automatically.

Hobbing machines became widespread in the early 20th century as demand for mass-produced gears grew with the automotive and machinery industries. They’re fast, accurate, and well-suited to spur gears, helical gears, and worm gears in medium-to-high volumes.

Best for: Production runs, spur and helical gears, worm gears.

Not ideal for: Internal gears or where access is restricted.

Gear Shaping — The Versatile Option

A gear shaper uses a reciprocating cutter that looks like a gear itself. It plunges into the blank and moves up and down while the blank and cutter rotate together incrementally — slowly generating the tooth form with each pass.

Gear shapers date back to the late 1800s, with the Fellows Gear Shaper Company (founded 1896 in the US) being one of the most influential manufacturers. The method is slower than hobbing but far more versatile — it can cut internal gears, cluster gears, and gears close to a shoulder where a hob couldn’t reach.

Best for: Internal gears, cluster gears, blind shoulders, lower volumes.

Not ideal for: High-volume production where speed matters.

Gear Milling — The Accessible Method

Gear milling uses a form-relieved cutter on a standard horizontal or universal milling machine with a dividing head to cut one tooth space at a time. The blank is indexed around between each cut.

This is the oldest and simplest method — gear milling was common in workshops long before dedicated hobbers or shapers were practical or affordable. It doesn’t require specialised machinery, just a mill and the right cutter set. Accuracy is lower than the other methods and it’s slow, but for one-off repairs, replacement gears, or prototype work it’s still widely used today.

Best for: One-offs, repairs, prototype gears, workshops without dedicated gear machinery.

Not ideal for: Tight tolerances or production volumes.

Which Machine Do You Need?

Hobbing MachineGear ShaperMilling Machine + Dividing HeadSpeedFastModerateSlowAccuracyHighHighModerateInternal gearsNoYesNoSpur/helical gearsYesYesYesCost of entryHigherModerateLowerBest useProductionVersatile/generalRepairs & one-offs

The Tooling Matters as Much as the Machine

A gear cutting machine is only as good as the tooling running in it. Hob geometry, grade, coating, and pitch all affect surface finish, tool life, and the accuracy of the finished gear — particularly in production environments where consistency matters.

Newmac Equipment is an authorised agent for two of the world’s leading gear cutting tooling manufacturers: DTR and Star SU.

DTR (formerly Dragon Precision Tools) has been producing high-performance cutting tools from Incheon, South Korea since 1976. With three manufacturing facilities and export reach across the US, Europe, Japan, India, and beyond, DTR produces over 3,000 hobs per month for customers in automotive, aerospace, wind energy, mining, construction, and general engineering.

Their range covers:

Involute gear hobs

Worm and chain sprocket hobs

Timing pulley, serration, and spline hobs

Special profile cutters

Shaper cutters and milling cutters

All tools are manufactured to AGMA, DIN, JIS, and ISO standards, with modules from 0.5 to 32. Three tolerance grades are available depending on your application:

A Grade — General Purpose: Standard tolerances, suited to jobbing shops, low-volume runs, and maintenance work where basic accuracy is acceptable.

AA Grade — High-Quality Production: Tighter tolerances with improved precision and repeatability. The right choice for medium-to-high production where consistent finish and tool life matter.

AAA Grade — Critical Tolerance: Built for the most demanding applications — aerospace, defence, and precision gear production where specifications are tight and quality cannot be compromised.

DTR hobs are produced using premium steels including M2, M35, ASP30, and ASP60, with wear-resistant coatings and final inspection on Klingelnberg systems. Ground on Reishauer CNC grinders, they’re a serious tool for serious production.

View our current DTR range and request a quote at newmac.com.au/gear-cutters-hobs

We’re also agents for Star SU — more on their range to follow in a future post.

At Newmac equipment we currently have gear cutting machines and the tooling to run them

Whether you’re after a hobber, a gear shaper, or cutters for an existing machine, we can help. We occasionally have gear cutting machines through stock and carry DTR and Star SU tooling for enquiry and order.

04-06-2026

3 Phase Power & Plug Connections — What You Need to Know

If you’ve purchased or are considering purchasing a 3 phase machine, one of the most common questions we get asked is: “Does it come with a plug?” Generally speaking, the answer is no — and here’s why.

How 3 Phase Machinery Is Disconnected

When industrial machinery is decommissioned from a factory or workshop, it is typically disconnected directly from a switchboard by an electrician. This means the machine leaves its previous home without a plug fitted, and in some cases the cable itself may also be absent. This is simply how the process works at an industrial level — it has nothing to do with the age or condition of the machine.

What This Means When You Buy Second Hand

As a machinery dealer, we are not electricians and are unable to supply or fit plugs. What we can tell you is that this situation is no different to buying a brand new 3 phase machine. New machinery purchased through any supplier or manufacturer also arrives requiring a licensed electrician for installation and connection. Second hand or new, 3 phase machinery requires a professional to get it running safely and legally.

If you don’t already have a relationship with an electrician, it’s worth organising one before your machine arrives. Connection is usually straightforward for a qualified tradesperson, and having it sorted in advance means no delays getting your equipment up and running.

When a Plug Is Already Fitted

On occasion, a machine will come into our inventory with a plug already fitted — perhaps from a smaller workshop setting where it was connected that way originally. In those cases, the plug stays with the machine. For the same reason we don’t fit plugs, we don’t remove them either.

The Bottom Line

3 phase connection is a licensed electrical job — full stop. Plan for it, budget for it, and you’ll have no surprises when your machine arrives.

29-05-2026

Old vs Modern Engineering – 1950’s Gleason vs Modern CNC Gear Cutting

One of the more interesting machines we currently have in stock is a Gleason 12” Straight Bevel Gear Generator, originally built in the 1950’s.

For those unfamiliar with the name, Gleason has a massive place in engineering history. The company was founded in 1865 in Rochester, New York, and became one of the world leaders in gear manufacturing technology. In 1874, William Gleason invented one of the first successful bevel gear planers, helping revolutionise the way gears were manufactured. Over the decades Gleason machinery was used in industries ranging from automotive and mining through to aerospace and military production.

What makes these older machines fascinating is that they were built for precision, durability, and long service life. Many of them are still operating today, over 70 years after they were built.

Our Gleason 12” Straight Bevel Gear Generator was designed to cut straight bevel gears mechanically using change gears, cams, and precision engineering — all without CNC controls, computers, or digital automation. Yet these machines were capable of producing highly accurate gears for serious industrial applications.

Fast forward to today, and to perform the same type of work you would generally be looking at a modern CNC bevel gear cutting machine from manufacturers such as Gleason, Klingelnberg, or similar European/Japanese builders. Modern machines now feature:

Full CNC control
Multi-axis servo systems
Automatic setup
Digital gear correction
Integrated inspection systems
Automation capability

The interesting part is the cost comparison.

Our 1950’s Gleason 12” Straight Bevel Gear Generator is currently advertised for AU$12,000+GST

A modern CNC bevel gear generator capable of similar work can easily cost several hundred thousand dollars, and in many cases well over AU$1 million depending on size, automation, and capability.

That really puts into perspective just how much engineering value exists in some of these older machines.

Sometimes older machinery may not be the fastest option…
…but it is hard not to respect a machine that is still capable of doing its job properly after more than half a century.

What are your thoughts?
Would you rather own:

A heavy-duty mechanical machine from the 1950’s
or
A modern CNC gear cutting centre?

Stock # 4226
Gleason 12” Straight Bevel Gear Generator

13-05-2026

What the Budget means for you. Businesses can claim an instant tax break for purchases under $20,000

There were a few things in the latest Federal Budget that are worth knowing about if you’re running a business or thinking about buying machinery.

The main one is the continued instant asset write-off. In plain terms, it means if you’re eligible, you may be able to claim equipment purchases straight away at tax time instead of spreading it out over a number of years. That can make a real difference when you’re looking at upgrading gear or adding to your workshop, especially from a cash flow point of view.

There are also some small tax cuts and cost-of-living changes coming through. Nothing dramatic, but it does help a bit with take-home pay and general confidence, which often plays a role in whether businesses decide to invest or hold off.

On top of that, there’s still strong government spending going into infrastructure and defence projects. That generally means ongoing work for engineering, machining, and fabrication industries, which is a good sign for demand in the background.

Overall, it’s not a huge shift in the economy, but it does lean slightly in favour of people who are looking to invest in equipment and keep their business moving forward.

If you’re thinking about upgrading machinery or planning ahead, it’s probably a good time to start having those conversations.

24-04-2026

Ever wondered what spindle nose your lathe actually has?

Most people are familiar with the Camlock (D1) system, as it’s one of the more commonly seen setups on modern lathes. But there are several other spindle mounting systems out there.

You will still come across things like:

• Long taper (Type L) spindle noses (generally found on older lathes)

• Short taper with bayonet-style fixing

• A-type spindle mounts (A1 / A2 – bolt-on type)

All of these systems use a taper to locate the chuck or faceplate on the spindle. Where they differ is in how the mounting is pulled into the taper and secured in place.

Depending on the design, this may be done using a locking ring, cam pins, studs, or bolts.

The important thing to be aware of is that these systems are not interchangeable without the correct backplate or adaptor. Knowing exactly what spindle nose you have is critical when buying tooling or machinery.

We’ve put together a page that covers these less common spindle nose types. Click here for more details:

10-04-2026

This week we’re focusing on smaller items — the sort of gear that doesn’t always get the spotlight but ends up being used every day.

Things like:
• Dividing heads
• Bench tools
• Tooling and accessories

These are often the pieces that finish off a setup or make a job possible without tying up a larger machine.

We’ve currently got a range of smaller equipment and accessories available, most in good working order and ready to go straight into use.

If you’ve been meaning to fill a gap in your workshop or pick up something practical without spending big money, it’s worth having a look.

As always, you’re welcome to drop in during business hours.

We buy and sell used engineering machinery and can assist with inspections and freight Australia-wide if required.

27-03-2026

When Global Supply Is Uncertain, Options Matter.

With everything going on around the world at the moment, it’s a reminder of how connected manufacturing has become.

Events in places like the Middle East can influence shipping, supply chains, and delivery times — sometimes in ways that aren’t immediately obvious.

In saying that, the industry is very good at adapting, and businesses are always finding practical ways to keep things moving.

One option that continues to make sense for many workshops is looking at good quality used machinery that is already here and ready to go.

Being able to inspect a machine, know exactly what you’re getting, and put it straight into service can take a lot of the uncertainty out of the process.

It’s not about one being better than the other — new machines have their place — but having options is important, particularly when timing and reliability matter.

Older machines were often built to a very high standard, with solid construction and simple, proven designs. Many are still working reliably today, which is why they continue to be a popular choice alongside newer equipment.

Just something to consider.

If you’re weighing up your options, feel free to have a look through what we currently have available or get in touch.

20-03-2026

This week we’re highlighting a new arrival – Atlas Copco GA15 VSD Screw Air Compressor (2020)
We’ve just taken delivery of a very tidy, late-model Atlas Copco GA15 VSD air compressor – a good example of a quality unit that hasn’t seen a lot of use.
With only 2,363 hours from new (averaging just over 8 hours per week), this machine presents in excellent condition and is ready to go straight into service.
The Variable Speed Drive (VSD) system automatically adjusts output to match demand, helping reduce power consumption compared with fixed-speed units. Ideal for workshops looking to improve efficiency without compromising on performance.
Key Details:
• 15 kW (20 HP) motor
• Approx. 2.45 m³/min @ 8.5 bar
• Quiet operation (~69 dB)
• Direct drive system
• Elektronikon controller
Fitted with:
• Air receiver
• Air dryer
A compact, reliable setup suited to engineering workshops, fabrication, or general industrial use.
For further details and pricing, please get in touch.

Click here for more details

27-02-2026

It’s been a busy and varied week here at Newmac Equipment.

We’ve seen strong interest in woodworking machinery, with a couple of those machines now sold and heading off to their new workshops.

To assist one customer and save them travelling to inspect in person, we filmed and posted a video of the machine running. We’re not woodworking specialists, but we managed to muddle through and provide what was needed. The video gave them the confidence to proceed.

The finishing touches have also been completed on a Colchester centre lathe, including the fitting of a new DRO system prior to dispatch. It’s always satisfying to see a good machine leave here ready to go straight into service.

An ESAB TIG welder has also found a new home this week.

At the same time, new stock continues to arrive — including a 3.2 metre x 120 tonne Durma press brake which has just come in.

Machines going out, machines coming in — that’s how we like it.

If you’re looking to buy, sell, or upgrade workshop equipment, feel free to get in touch.

20-02-2026

Buying your first used machine? Start here.

If you’re buying your first used machine, it can feel overwhelming. There’s plenty of advice out there, and not all of it is useful.

Here are a few practical things worth focusing on.

What matters

Whether the machine suits the work you actually do (not just what you might do one day)
Power requirements and whether your workshop can supply it
Size, weight, and how the machine will be moved into position
Overall condition and how the machine has been used

What doesn’t matter as much as people think

Age on its own
Fresh paint or cosmetic appearance
Optional features you’re unlikely to use

A well-built older machine in sound condition will often outperform a newer machine that isn’t suited to the job.

What to ask and look for

Can the machine be seen running?

(Yes —we’re happy to demonstrate machines running.)
What tooling or accessories are included?

(Anything included is listed and shown in the photos.)
Are there any known issues or limitations?

(We normally include a PDF report on each listing outlining any known issues.)
Can a freight quote be supplied?

(Yes — we’re happy to assist with freight quotes.)

Take your time, ask questions, and don’t be afraid to inspect in person. The right first machine should make your work easier, not create problems.

Inspections are always welcome during business hours.

13-02-2026

This week’s post is a bit left field, but it’s something that causes more confusion than it probably should.

Every so often we get a call from a customer who’s just installed a machine and it doesn’t seem to be behaving properly — motors running the wrong way, no hydraulic pressure, no coolant flow, or a CNC machine throwing an alarm that doesn’t really point to anything obvious. In a lot of cases, the machine is actually fine and the issue turns out to be incorrect phase rotation at the power supply.

To help save time, frustration, and unnecessary downtime, we’ve put together a short, practical guide on checking three-phase rotation. It applies to both conventional and CNC machines and explains what to look for before assuming there’s a fault with the machine itself.

Click here to download the procedure

06-02-2026

A quick update on our activities this week

We regularly receive emails and phone calls from customers looking to sell machinery. In some cases, for practical reasons, we don’t purchase these machines straight away. This can be due to space constraints, the physical size or weight of the machine, or handling and transport considerations. Even so, we’re often still aware of these machines and can discuss them with interested buyers.

As a result, we’re currently aware of a number of machines that may be available, even though they’re not formally advertised or listed for sale at this stage.

The photos below show a selection of machines we’re aware of and are being shared to gauge interest. If something catches your eye, let us know and we can provide further details, confirm availability, and discuss whether it may be suitable for your application.

Not all opportunities come through standard listings, and in many cases it’s enquiry that starts the conversation rather than a formal advertisement.

We buy and sell used engineering machinery and can assist with inspections and freight Australia-wide if required.

30-01-2026

A lot of what we do happens long before a machine is ever listed or talked about. There’s a fair bit of background work — checking, measuring, running machines, and thinking through the details — that most people never see, but it’s what makes the difference in the end.

This week has mostly been about doing those checks properly, answering the less obvious questions, and making sure customers have enough information to feel confident in their decision — not just a price and a spec sheet.

That means taking the time to run machines, inspect wear where it actually matters, and explain what we’re seeing in plain language. It also means sorting out the practical side early — power requirements, access, loading, and freight — so there are no surprises once things move ahead.

We’re always upfront about what we know and what we don’t. Used machinery isn’t new, and pretending otherwise doesn’t help anyone. Spending the extra time at the start usually saves time, cost, and frustration later on.

If you’re looking at used machinery and want clear, straightforward information rather than sales talk, you’re welcome to get in touch or drop in during business hours.

For anyone interested, we’re now also sharing a short weekly update on Facebook covering what we’ve been working on behind the scenes — please click here to take a look.