Gear manufacture process by using chilled ductile iron casting

Abstract Ductile Iron has been used many times for the manufacture of components by casting, one of them is gears. The gear manufacturing method is one of the determinations of gear performance in service life. Wear and contact fatigue are important cases to consider during gear operation and the cause is surface hardness and dimensional accuracy. The purpose of this study was to investigate the surface behavior and gear profile dimension accurately. Gear chilled casting using an open mold made of silica sand. The chill will be coated to the surface of the mold wall then pouring at a temperature of 1400oC. Chill creates a good cooling rate on the surface to form FeC3 and M7C3 and (FeCrC)7C3, then produce a hardness of 700-994.96HV. Using chill thickness is 0.4mm, the dimensional accuracy of tooth thickness, pitch circular, and addendum circle diameter is very precise after the finishing process.