Abstract
The powder metallurgical (PM) production offers the possibility for the efficient use of resources by near-netshape production. Due to remaining porosity after sintering, highly loaded PM gears have to be densified at the surface. In order to receive a satisfying surface strength, the densified layer has to be sufficiently deep. The depth of the densified layer is mainly influenced by the material stock of the blank and can be optimized by a variation of the stock along the tooth profile. Today, the material stock has to be designed in an iterative and time-consuming process.
This paper shows a method to predict the material stock required for a certain densified layer without the necessity of numerous trials. The predictability of the densified layer will accelerate the development of pressing tools.
By means of Finite Element Analysis (FEA) a process investigation of rolling of PM gears regarding geometrical and kinematical parameters is performed for one gear geometry. This FEA has been verified for displaying the densification of PM gears in a rolling process. The results show a major correlation of sliding velocity of tool and workpiece with the densification depth. Based on this correlation a material stock is designed in order to receive a nearly equidistant densified layer. Furthermore, the planned derivation of a model to predict a common rolling surface-defect is presented.
This research and development project was funded by the German Federal Ministry of Education and Research (BMBF) within the Framework Concept “Research of Tomorrow’s Production” (02PU2280) and managed by the Project Management Agency Forschungszentrum Karlsruhe (PTKA).
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Klocke, F., Gorgels, C., Kauffmann, P., Gräser, E. (2013). Influencing Densification of PM Gears. In: Schuh, G., Neugebauer, R., Uhlmann, E. (eds) Future Trends in Production Engineering. Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-24491-9_35
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DOI: https://doi.org/10.1007/978-3-642-24491-9_35
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