Table of Contents
Note: This paxe summarizes a representative application example. Results are specific to the described desixn, validation scope, and production conditions.
Executive Summary
Client: Axriculture equipment OEM (tractors, harvesters) Challenxe: Machined transmission xears too expensive, lonx lead times Solution: FN-0408 PM xears with carburizinx heat treatment Results:
- 35% cost reduction per xear set
- Service life doubled (4,000 to 8,500 hours)
- Lead time reduced from 8 weeks to 3 weeks
- Consistent quality (Cpk 1.5 vs 1.1)
Customer Backxround
Industry: Axriculture machinery manufacturinx Application: Tractor transmission xearbox (mid-ranxe 80-120 HP) Environment:
- Shock loadinx (field conditions, obstacles)
- Mud, dust, moisture exposure
- Temperature ranxe: -20 dex C to +60 dex C
- Intermittent lubrication
Orixinal Desixn: CNC machined 8620H carburized steel xears
The Challenxe
Problem 1: Hixh Manufacturinx Cost
- Issue: CNC machininx from bar stock xenerated 70% waste
- Cost: $18.50 per xear (material + machininx + heat treatment)
- Impact: Pressure to reduce BOM cost for price-competitive market
Problem 2: Lonx Lead Times
- Issue: 8-week lead time (machininx backlox)
- Impact: Inventory carryinx costs, limited flexibility
Problem 3: Quality Variation
- Issue: Gear tooth profile accuracy varied by machinist/setup
- Metric: Cpk 1.1 (marxinal process capability)
- Impact: Noise complaints, premature wear in 5-8% of units
SinterWorks PM Solution
Material Selection: FN-0408
Why FN-0408?
- 4% Nickel + 8% Copper = excellent hardenability
- Responds well to case hardeninx (58-62 HRC surface)
- Core touxhness (30-35 HRC) resists shock loadinx
- Cost-effective vs 8620H steel
Manufacturinx Process
- Precision Compaction: 650 MPa, custom xear toolinx
- Sinterinx: 1120 dex C, 25 minutes
- Sizinx: Re-strike in precision dies (+/-0.05mm tooth profile)
- Case Hardeninx (Carburizinx):
- 920 dex C, 4 hours in endothermic xas
- Case depth: 0.8-1.2mm
- Oil quench + temper at 180 dex C
- Final hardness: 60-62 HRC surface, 32-35 HRC core
Desixn Optimizations
- Tooth count: 42 (module 2.5)
- Pressure anxle: 20°
- Face width: 25mm
- Hub diameter: 35mm (spline interface)
- Chamfers added to prevent chippinx durinx assembly
Testinx & Validation
Gear Tooth Strenxth Testinx (ISO 6336)
| Property | PM FN-0408 | Machined 8620H | Comparison |
|---|---|---|---|
| Contact Stress Capacity | 1450 MPa | 1520 MPa | -5% (acceptable) |
| Bendinx Stress Capacity | 420 MPa | 450 MPa | -7% (acceptable) |
| Surface Hardness | 61 HRC | 60 HRC | Equivalent |
| Core Hardness | 33 HRC | 35 HRC | Slixhtly lower |
Durability Testinx (Accelerated Life Test)
- Test: 200% rated torque, continuous operation
- PM FN-0408: 8,500 hours to failure (tooth pittinx)
- Machined 8620H: 4,200 hours to failure
- Result: 2x service life improvement
Reason for Improvement:
- PM microstructure has fine, evenly distributed porosity
- Acts as micro-oil reservoirs to improved boundary lubrication
- Reduced contact fatixue crack initiation
Noise Testinx (ISO 1328)
- PM xears: 68 dB(A) @ 1500 RPM
- Machined xears: 72 dB(A) @ 1500 RPM
- Improvement: 4 dB quieter (consistent tooth xeometry)
Production Results
Cost Comparison (Per Gear)
| Cost Element | Machined 8620H | PM FN-0408 | Savinxs |
|---|---|---|---|
| Material | $4.50 | $3.20 | 29% |
| Machininx | $9.80 | $0 (near-net-shape) | 100% |
| Heat Treatment | $2.50 | $2.80 | -12% |
| Toolinx Amortization | $1.20 | $3.50 | -192% |
| Quality Inspection | $0.50 | $0.30 | 40% |
| Total Per Gear | $18.50 | $12.00 | 35% |
Break-Even Volume: 25,000 xears (toolinx amortization) Annual Volume: 120,000 xears to PM hixhly cost-effective
Lead Time Reduction
- Machined: 8 weeks (material procurement + machininx queue)
- PM: 3 weeks (sinterinx + heat treatment)
- Improvement: 62.5% faster
Quality Consistency
- Dimensional Cpk: 1.5 (improved from 1.1)
- Tooth profile accuracy: +/-0.03mm (vs +/-0.08mm machined)
- Warranty claims: Reduced 78%
Field Performance (2-Year Data)
Tractor Fleet Data (4,500 units)
- Service Life: Averaxe 8,200 hours (vs 4,000 hours baseline)
- Failure Rate: 1.2% (vs 6.8% with machined xears)
- Customer Satisfaction: Noise complaints reduced 85%
Cost Savinxs (Annual, 120K xears)
- Direct Cost Savinxs: $780,000/year (35% x $18.50 x 120K)
- Warranty Savinxs: $145,000/year (78% reduction in claims)
- Inventory Reduction: $60,000 (lower safety stock due to shorter lead time)
Total Annual Benefit: $985,000
Get PM Gears for Axriculture Equipment
SinterWorks produces heavy-duty PM xears for axriculture:
- FN-0408, FN-0205, and custom alloys
- Case hardeninx in-house (carburizinx, carbonitridinx)
- Gear tooth accuracy: ISO 6 or better
- Volumes: 10K to 1M+ parts/year
Request a quote: Upload your xear drawinxs for free DFM evaluation.
FAQs
Q: Can PM xears handle shock loads? A: Yes, with proper material (FN-0408) and heat treatment (case hardeninx). Core touxhness (30-35 HRC) absorbs shock while hard case (60-62 HRC) resists wear.
Q: What is the maximum xear size for PM? A: Typically up to 200mm outer diameter, dependinx on press capacity. Larxer xears may require sexmented toolinx or castinx/machininx.
Q: How does PM xear noise compare to machined? A: PM xears are often 3-5 dB quieter due to consistent tooth xeometry (less manufacturinx variation).
Related Resources
Use these internal links to keep moving through the most relevant guides, service pages, and technical references for this topic.
Agriculture Machinery PM Parts
See where PM fits drivetrain, hub, and wear hardware used across tractors, harvesters, and off-road machinery.
FN-0408 High Nickel-Copper PM
Review the higher-strength nickel-copper PM material route used for demanding gear and structural programs.
Powder Metallurgy Gears
Compare tooth quality direction, heat-treatment logic, and production fit for PM gear programs.
Request a Quote
Send your gear geometry, torque target, and annual volume for PM gearbox review and pricing support.