Micro Gear Manufacturing: MIM vs Powder Metallurgy Comparison
Gear Materials
Micro gear manufacturing uses Fe-2Ni for general purpose, 17-4PH for corrosion resistance and bronze for self-lubricating gears. Gear quality ISO 6-9. Surface densification by rolling improves tooth flank density.
Heat treatment options: sinter hardening, carburizing, steam treatment for wear resistance.
| Material | Density | Hardness | Use |
|---|---|---|---|
| Fe-2Ni | 7.2-7.4 | HRB 80 | General |
| Fe-Ni-Mo | 7.3-7.5 | HRB 90 | Higher strength |
| 17-4PH | 7.4-7.6 | HRC 35-44 | Corrosion |
| Bronze | 7.0-7.2 | HB 60 | Self-lubricating |
MIM vs PM Process
MIM achieves higher density (7.4-7.6 g/cm³) with finer detail. Tooling: MIM $7-20k, PM $10-30k. MIM for gears under module 0.5 under 50g. PM for module 0.5-3.0 larger gears. Both require tumbling for edge deburring.
MIM advantage: sharper tooth profiles. PM advantage: lower material cost for larger gears. Surface finish Ra 0.8-1.6 post-tumbling.
| Parameter | MIM | Powder Metallurgy |
|---|---|---|
| Density | 7.4-7.6 g/cm³ | 6.8-7.4 g/cm³ |
| Module Range | 0.2-0.8 | 0.5-3.0 |
| Tooth Quality | DIN 7-9 | DIN 6-8 |
| Volume Economy | 5,000+ | 10,000+ |
Quality Control
Tooth profile with gear analyzer. Single-flank roll testing for transmission error. Hardness per HRB/HRC. Runout <20μm. Noise testing in assembled gearbox. Torque-to-failure for planetary sets.
Backlash measurement for precision applications. Surface roughness verification with profilometer.
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