Metallic Powder Gears
Gear Motions for a Helical Powdered Metal Gear
Powder metallurgy is the method used to create powdered metal gears. The popularity of powdered metal as a gear material has increased as a result of numerous improvements made to this technology throughout time.
Although utilized in numerous industries, the automotive industry uses powdered metal gears the most. Engine components like sprockets and pulleys, gear shifters, oil pump gears, and turbocharger systems are examples of common automobile applications. Bevel gears, helical gears, and spur gears can all be made using powder metallurgy.
Powder metallurgy: What is it?
Metal pieces can be formed using a method called powder metallurgy. The procedure is broken down into three steps:
the metal particles being combined
forming the correct shape by compacting the granules
Heating the compressed form under regulated circumstances
Depending on the level of precision required, the outcome is a metal item that is almost exactly the intended shape and needs little to no machine finishing.
The benefits and drawbacks of powdered metal gears
Cost may be the main factor in choosing powdered metal gears over more conventional gear materials. A gear made of metal powder is less expensive to produce in large quantities than a gear made of iron or steel. First off, there is extremely little material waste and less energy is utilized during production. When you take into account that many powdered metal parts don’t need much, if any, machine polishing, the manufacturing cost is also typically lower.
Powdered metal also has other advantages related to the composition of the material. Powdered metal gears are lightweight and often run silently because of their porous construction. Additionally, the powder material can be uniquely combined to create distinctive properties. For gears, this entails the chance to permeate the porous material with oil, producing self-lubricating gears.
Powdered metal gears can have some disadvantages, though. One of the most important is that powdered metal is less durable than other materials and ages more quickly. In order to retain the equipment’s ability to be manufactured and its efficacy, there are also size restrictions. Producing powdered metal gears in small- to medium-sized production volumes is typically not cost-effective.
Machine Finishing on Gears Made of Powdered Metal
We already mentioned that machine finishing is not as necessary for pieces made of powdered metal. However, there are situations in which a powdered metal gear needs to undergo extra machining. For instance, the powder metallurgy method is unable to reach the high level of precision needed for particular gears used in critical applications.
Gear Motions, a maker of precision gears, has the ability to polish powdered metal gears in a number of ways. This includes grinding helical and spur gears with precision. Precision gear grinding is one finishing procedure that results in precise tooth profiles and a high-quality surface finish.
On blanks of powdered metal, we can also undertake gear cutting operations to create gear teeth. Given that powder metallurgy can be challenging to employ for creating angled teeth, this technique is especially helpful when creating helical gears.
Gear Motions is well-equipped to meet all of your gear production demands thanks to cutting-edge manufacturing equipment and a knowledgeable workforce. Ask us a question or request a quote right away.