Dura-BarGear manufacturers can dramatically lower their machining costs and produce quieter gears by switching from free machining carbon steels to Dura-Bar continuous cast iron barstock.
Dura-Bar's cost advantage over steel stems from its unparalleled material consistency and superior machinability which allow Dura-Bar to be machined with higher speeds and feeds. Cycle times for machining gear blanks and hobbing teeth can be cut by as much as 50%. Also, the need for deburring is greatly reduced or even eliminated.
Other advantages gained by switching from steel to Dura-Bar include:
• Quieter Operation - Dura-Bar's superior vibration damping characteristics means gears made from Dura-Bar will be quieter than steel gears made to the same dimensional tolerances.
• Less Heat-Treat Distortion - Material growth that occurs during heat treating is more predictable with Dura-Bar, thereby minimizing additional processing steps. Also, since Dura-Bar does not need to be carburized, heat-treat distortion due to variations in the rate of carbon diffusion into a gear is eliminated.
• Comparable Strength - As-cast Dura-Bar is available in gray and ductile iron with tensile strengths ranging from 35,000-100,000 psi, with strengths up to 230,000 psi obtainable with heat treating. Strengths up to 90% of those in 8620 carburized and hardened steel and 80% of those in 4140 through hardened steel are readily obtainable by proper heat treating of Dura-Bar.
• Better Wear Resistance - When quench and tempered or austempered, Dura-Bar will outperform heat-treated steel when it comes to wear. Graphite particles in Dura-Bar's microstructure reduce localized thermal stresses and prevent the friction welding that causes galling.
Find out more about the advantages of Dura-Bar over steel by ordering our free Steel Alternative Kit by calling 1-800-BAR-MILL (800-227-6455) or visiting our web site at www.steelalternative.com.
Dura-Bar: The Alternative to Steel in Gear Manufacturing
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