Analyzing Gear Blank Failure: A Comprehensive Industrial Case Study

This study analyses a cold-forged gear blank failure that was reported by the industry. In cold forged metal, the damage is seen as fissures running parallel to the thickness direction. Visual inspection, composition analysis, hardness, microstructure, residual stress measurement, and non-destructive testing like magnetic particle inspection, ultrasonic detection, and radiographic tests were performed and analyzed to investigate the problem. The thorough research found that the crack appeared during the material's evolution's earliest stages and acceptance standards. The same has been discussed with the end user to ascertain that this type of failure should not occur again. The objectives, methods, and anticipated results of the study are briefly summarised in the abstract. The project intends to provide significant insights to the field of mechanical engineering, leading future developments in gear design, manufacture, and performance optimisation by a thorough analysis of the failure evaluation of a gear blank. The significance of this investigation is due to its ability to improve the design and production of gear blanks and related components. Engineers and designers can improve the material choice, manufacturing processes, and operational circumstances by identifying the primary reasons of failure and comprehending the crucial aspects that caused the malfunction. As a result, gear systems may perform better, last longer, and be more reliable in a variety of applications.