Factory Sintering Gear
Sintered gears are gears manufactured using powder metallurgy technology. Metal powders are mixed in proportion and pressed into shape in a mold. The powder particles are then bonded into dense metal workpieces through high-temperature sintering. Finally, performance can be improved through post-treatment such as finishing and oil immersion. It is one of the most widely used categories in powder metallurgy parts, widely used in fields such as automobiles, home appliances, and power tools.
- Product Introduction
Product Details
|
Commodity |
Factory customized high precision strong wear resistance sintering gears |
| Modular range | 0.1-2.0mm |
| Number of teeth range | 10-100 teeth |
| Outer diameter tolerance | ±0.01mm - ±0.03mm |
| Tooth surface roughness | Ra0.8-Ra3.2μm |
| Density | 6.0-7.2g/cm³ ( iron based ) |
| Tensile strength | 300-800MPa |
Production Process
1. Powder preparation
• According to the performance requirements of the gear, mix iron powder, copper powder, graphite powder and other raw materials in precise proportions, and also add lubricants and forming agents to improve the compression performance .
• The mixed powder should have uniform composition and good flowability to ensure consistency in compression molding .
2. Compression molding
• On a dedicated powder metallurgy press, place the mixed powder into a precision mold, apply a pressure of 150-700MPa, and press it into a green body that is close to the shape of the gear .
• The green body has a certain strength and can be transported and processed afterwards .
3. High temperature sintering
• Place the green body into the sintering furnace and heat it to 1100-1300 ℃ under a protective atmosphere (such as ammonia decomposition gas, hydrogen gas), and keep it at that temperature for a period of time .
• Powder particles combine through processes such as atomic diffusion and fusion to form a dense metallic structure, obtaining mechanical properties similar to forged steel .
4. Post processing procedures
• Finishing/shaping: Cold press correction of sintered gears through molds to improve dimensional accuracy and surface smoothness .
• Oil immersion treatment: Immerse the gear in lubricating oil, utilizing the oil absorption properties of the pores to give the gear its own lubrication performance, reducing the lubrication steps required for subsequent assembly .
• Heat treatment: Some high-performance gears require carburizing quenching, induction hardening, etc. to further improve hardness and wear resistance .
• Surface treatment: such as galvanizing, phosphating, etc., to enhance the rust prevention ability of gears .
Sintering Gear Classification
Classified by gear type
• Cylindrical gear: The most widely used type, with tooth lines parallel to the axis, used to transmit power between parallel shafts, commonly found in automotive transmissions, power tools, and other scenarios.
• Bevel gear: The tooth profile is conical and used to transmit power between intersecting axes, such as in car differentials and steering systems.
• Worm gear: The worm gear is used in conjunction with the worm wheel to transmit power along a vertical staggered axis, while also achieving a large reduction ratio. It is commonly used in precision transmission equipment such as machine tools and automated production lines.
• Planetary gear: Composed of sun gear, planetary gear, and internal gear ring, with small volume and large transmission ratio, commonly used in new energy vehicle reducers, robot joints, and other fields.
Classified by sintering process
• Conventional sintered gears: Using ordinary powder metallurgy sintering process, heated to a temperature lower than the melting point of the base metal in a protective atmosphere, to bond the powder particles, with low cost, suitable for mass production of universal gears.
• Carbonized and sintered gears: During the sintering process, carburizing treatment is carried out to improve the surface hardness and wear resistance of the gears. It is commonly used in transmission parts that can withstand heavy loads and high friction, such as the rear axle gears of automobiles.
• Re pressing and re firing gears: Sintering first followed by secondary pressing and secondary sintering can further improve the density and strength of the gears, with performance similar to forged gears, and can be used to replace some traditional forged gears.
Classified by sintered materials
• Iron based sintered gears: using iron powder as the main raw material, with low cost and moderate strength, it is currently the most mass-produced sintered gear type, widely used in various general machinery.
• Copper based sintered gears: With high copper content, they have good anti friction and thermal conductivity, making them suitable for use in low-speed, light load environments with noise control requirements, such as transmission components of office equipment.
• Stainless steel sintered gears: With excellent corrosion resistance, they are commonly used in scenarios such as food processing machinery and marine environmental equipment that have strict requirements for rust prevention.
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