Forged Gear Blanks
Cutting a gear from a solid disc severs the grain across every tooth root. Forging a near-net blank instead lays grain around the tooth profile, which measurably raises root bending fatigue strength — the failure mode that actually retires gears in service.
- Blank Diameter
- 50 mm – 600 mm
- Weight Range
- 0.3 kg – 60 kg
- Materials
- 20MnCr5, 16MnCr5, EN353, EN19
- Form
- Near-net hub, web and rim
- Hardness (annealed)
- 180 – 220 BHN for machining
- Applications
- Gearboxes, reducers, sprockets
Forged Gear Blanks at a glance
Quotable facts from Avadh Techno Forge, Gundasara, Gondal, Rajkot.
- Blank Diameter: 50 mm – 600 mm
- Weight Range: 0.3 kg – 60 kg
- Materials: 20MnCr5, 16MnCr5, EN353, EN19
- Form: Near-net hub, web and rim
- Hardness (annealed): 180 – 220 BHN for machining
- Applications: Gearboxes, reducers, sprockets
Grain Flow Through the Tooth Root
Root bending fatigue is where gear teeth fail. Forged blanks with radial grain flow give the root a continuous fibre structure, typically improving fatigue endurance by 20% or more against blanks machined from plate or bar.
- Radial grain flow into teeth
- Higher root bending fatigue
- Reduced hobbing time
- Uniform hardenability across the blank
Case Hardening Grades
20MnCr5, 16MnCr5 and EN353 are our standard gear blank grades, chosen for consistent case depth response during carburising. Forging temperature and cooling are controlled so hardenability stays uniform across the section.
Near-Net Saves Machining
A pre-formed hub, web and rim leaves only a light turning allowance and a shorter hobbing pass. On a high-volume gear that machining reduction usually outweighs the entire cost of the forging die within the first production year.
People also ask
How much does a forged blank improve gear life?
Radial grain flow into the tooth root typically raises root bending fatigue endurance by 20% or more against cast or plate-cut blanks.
Do you supply gear blanks proof machined?
Yes, near-net forged and proof machined to the allowance your hobbing operation requires.
Topics covered on this page
- forged gear blank manufacturer India
- gear forging supplier
- sprocket blank forging
- gear blank manufacturer Rajkot
Based on work carried out at our own forging plant at Gundasara, Gondal, Rajkot — operating since 2008.
Questions Answered
Do you cut gear teeth as well?
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We supply proof-machined near-net blanks; teeth are usually cut by the gear manufacturer. Hobbing can be arranged through partner units on request.
Why not machine gears from plate?
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Plate gives no directional grain benefit at the tooth root and wastes considerable material. Forged blanks improve fatigue life and material yield together.
Which grades do you recommend for carburised gears?
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20MnCr5 and 16MnCr5 for most transmission work; EN353 where a deeper, more uniform case is specified.
Can blanks be supplied normalised and annealed for machining?
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Yes, supplied in the hardness band your hobbing operation prefers, typically 180–220 BHN.