Miter gears are typically manufactured from a range of materials, with the selection primarily driven by the application’s requirements for strength, durability, wear resistance, noise level, cost, and operating environment. The most common materials fall into the following categories:
- Steels (Most Common for High-Performance Applications)
- Non-Ferrous Metals
Brass/Bronze: Commonly used for the smaller gear in a pair (especially in worm gear sets where the worm is steel) due to good wear resistance, compatibility with steel, and lower friction. Also used in low-load, corrosion-resistant, or non-sparking environments.
Aluminum Alloys: Used where weight reduction is critical (e.g., aerospace, robotics). They have lower strength and wear resistance than steel, so they are suitable for moderate loads and speeds. Often anodized for surface hardness.
- Plastics & Polymers
Engineering Plastics (e.g., Nylon, Acetal/POM, Polycarbonate): Used for light to moderate loads where low noise, self-lubrication, corrosion resistance, and low cost are priorities. Common in consumer appliances, office equipment, and light-duty mechanisms. They are quieter and require less lubrication than metal gears but have lower strength, heat resistance, and dimensional stability.