Highly loaded gears are usually casehardened to fulfill the high demands on
the load-carrying capacity. Several factors, such as material, heat treatment, or macro and micro geometry, can influence the load-carrying capacity. Furthermore, the residual stress condition also significantly
influences load-carrying capacity. The residual stress state results from heat treatment and can be further modified by manufacturing processes post heat treatment, e.g. grinding or shot peening.
Despite the development and availability of a number of newly engineered, rugged materials intended for plastic gear applications, some engineers/designers continue to believe metal is better.