Introduction

For transmission of power, Gears have been in use since the dawn of civilization. Gears in the early stages were in the form of cylindrical discs having surface irregularities. These primitive transmission tools were adequate to meet the operational needs of those days.
The rapid industrialisation and development of precise equipments over the past century have set an entirely new set of demands on the present day transmission tool:'The Gears'. Today, the gears, apart from being just a kinematic link for transmission, should have inbuilt robust construction, long life, reliable, performance, high efficiency and economy.
The design and production of gears call for due consideration to make the gear drives noise free, chatter free, and ensure high load carrying capacity at constant velocity ratio. The gears are to be fatigue free and free from high stresses to avoid frequent gear failure.
To meet the above need and to facilitate production of a large quantity of quality gears, the machine tools and the processes of gear manufacturing have undergone phenomenal change.
At present, gears have found universal application. They are used in Automobiles, Agricultural machinery, Industrial machinery, Machine tools, gear boxes, Geared motors, Oil Engines and in many other industrial and consumer durable goods.

Materials for Gear Manufacture

Material
Suitability
Application
1. Cast iron
where stress on gears is not enough
gears with a large size and complicated shapes
2. Cast steel
where stress on gear is high
gears where fabrication is difficult
3. Carbon steels
where high toughness combined with high strength, fatigue limit in bending, long life and accuracy of teeth is required
industrial gears
4. Alloy steel
where tooth strength of gear is required to be high and tooth wear to be low
industrial and automobile gears
5. Case hardened steel
where gears are likely to bear varying loads and shocks
industrial gears
6. Surface hardening
where tooth surface is required to be very hard
gears used for transmitting shockless loads
7. Nitrided steel
where very high hardness(750-800 BHN) of gear tooth is required
aircrafts gears, marine propulsion gears etc.
8. Non ferrous material bronze.

Alluminium
where wear resistance and smooth running of gears is desired

where low inertia of rotating mass is desired

used for making worm wheels that run in mesh with hardened worms.
used for instrument gears and appliances

9.Non metallic gears
Leather, plastic, nylon etc
where low gear noise is desired and where the load transmitted is low
instrument gears and appliances, etc.

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Material	Suitability	Application
1. Cast iron	where stress on gears is not enough	gears with a large size and complicated shapes
2. Cast steel	where stress on gear is high	gears where fabrication is difficult
3. Carbon steels	where high toughness combined with high strength, fatigue limit in bending, long life and accuracy of teeth is required	industrial gears
4. Alloy steel	where tooth strength of gear is required to be high and tooth wear to be low	industrial and automobile gears
5. Case hardened steel	where gears are likely to bear varying loads and shocks	industrial gears
6. Surface hardening	where tooth surface is required to be very hard	gears used for transmitting shockless loads
7. Nitrided steel	where very high hardness(750-800 BHN) of gear tooth is required	aircrafts gears, marine propulsion gears etc.
8. Non ferrous material bronze. Alluminium	where wear resistance and smooth running of gears is desired where low inertia of rotating mass is desired	used for making worm wheels that run in mesh with hardened worms. used for instrument gears and appliances
9.Non metallic gears Leather, plastic, nylon etc	where low gear noise is desired and where the load transmitted is low	instrument gears and appliances, etc.