Net forged spiral bevel gear

A process for manufacturing a spiral bevel gear, comprising:

• providing a forging having a first side and a second side, the first side comprising a plurality of spiral bevel gear teeth, the forging being formed of metal;
• machining the second side of the forging to a predetermined distance from a portion of the spiral bevel gear teeth to form a machined forging;
• without machining the spiral bevel gear teeth, coining the machined forging to induce plastic flow in the spiral bevel gear teeth and cause the spiral bevel gear teeth to conform to a desired tooth profile with a desired degree of accuracy to thereby form a coined gear, wherein each of the spiral bevel gear teeth has a pair of flanks, and wherein the desired tooth profile includes a contour of the flanks of the spiral bevel gear teeth;
• heat-treating the coined gear to form a heat-treated gear;
• machining a portion of the heat-treated gear other than the flanks of the spiral bevel gear teeth to form a heat-treated, machined gear;
• and
• lapping the spiral bevel gear teeth on the heat-treated, machined gear with spiral bevel pinion gear teeth such that the spiral bevel gear teeth and the spiral bevel pinion gear teeth have a quality level in which they perform at or below a 50 micro-radian level of first harmonic transmission error when positioned in a predetermined spatial relationship.