Forged gears beat cut gears because of grain flow. Machining a gear from bar or plate cuts through the material's fiber structure right at the tooth flanks, where bending fatigue does its damage. A near-net or net-forged tooth keeps that fiber running along the profile, which reinforces the root fillet and the tooth's beam strength.
The gear blank is the quality ceiling of the finished gear. This article covers two areas of material specification that directly affect gear performance: controlling hardenability when sourcing blanks across global supply chains, and specifying microalloyed steels for high-temperature carburizing.
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