Which is cost saving between forged gear and machined gears?

When customers enquire about the manufacturing of gears, they frequently ask us which process is more cost-effective.

Determining which type of gear manufacturing process is more cost-saving, whether forged or machined, depends on various factors such as the complexity of the gear design(gear teeth, gear modular, gear shape), the required precision(ISO standard, AGMA standard, DIN standard), material properties(Low carbon steel,middle carbon steel,high carbon steel), production volume(annual gear purchase quantity above or below 20000pcs), and initial setup costs(R&D cost, include gear mould cost, gear hobbing cutter, shaping cutter, broaching cutter...etc). Here's a breakdown of considerations for both processes.

Forged Gears:

1. Initial Tooling Costs: Forging typically requires expensive tooling for dies and presses, leading to higher initial setup costs.

2. Material Savings: Forging can result in material savings since it can create near-net shape gears, minimizing waste.

3. Production Volume: Forging is often more cost-effective for high-volume production due to its faster production rates.

4. Strength and Durability: Forged gears tend to have higher strength and durability due to the grain structure of the material being aligned with the shape of the gear teeth.

Machined Gears:

1. Initial Setup Costs: While machining may have lower initial setup costs compared to forging, it can be higher for complex gear designs that require specialized machining equipment.

2. Material Waste: Machining typically generates more material waste compared to forging, especially for intricate gear designs.

3. Precision: Machining offers high precision and can achieve tight tolerances, making it suitable for applications requiring exacting specifications.

4. Flexibility: Machining allows for easier customization and modifications to gear designs compared to forging.

In summary, the cost-saving choice between forged and machined gears depends on factors such as production volume, design complexity, material properties, and required precision. For high-volume production with relatively simple gear designs, forging may be more cost-effective due to lower material waste and faster production rates. However, for low-volume production or applications requiring high precision and customization, machining may be the preferred option despite potentially higher initial setup costs.

Welcome to consult with our sales engineer, we will evaluate a reasonable price for you based on your gear technical requirement.

Contact us by info@minghua-gear.com

Thank you.