A method of forming a gear

摘要

The present invention provides a method of forming a gear comprising: machining a metal blank to form a component comprising a cylindrical hollow shaft having a gear wheel integral therewith which extends radially outwardly from a midpoint of the shaft, the gear wheel having indentations provided on substantially planar side surfaces thereof; sandwiching the gear wheel between a pair of washers; and applying a pair of conical or frusto-conical end stops to the machined component to engage apertures at the ends of the hollow shaft, the end stops acting to align the axis of the shaft with a chosen axis; then applying a pair of tools to the washers to force the washers against the substantially planar side surfaces of the gear wheel of the machined component to deform the metal of the washers to flow into the indentations on the side surfaces and thereby to secure the washers on the gear wheel.