Abstract
Increase in power density by optimizing the design of component geometry is a current trend in the development of powertrains for the automotive industry. Due to economic reasons, conventional cutting processes can only be used to a limited extent for implementing this lightweight concept. The presented development by Fraunhofer Institute for Machine Tools and Forming Technology IWU shows alternative process chains based on forming technology for near-net-shape manufacturing of complex components. By selecting suitable forming processes and by consistently developing them further, it is possible to save material, reduce the process time and improve the functional characteristics in manufacturing of hollow gear shafts. Hereby, a process route is demonstrated for manufacturing the hollow shape by applying the process of spin extrusion exemplary, thus eliminating high material losses of up to 30% occurring in deep-hole drilling. When combined with gear rolling, which has so far been limited to the production of so-called splines and which represents a resource efficient substitute for manufacturing gears by cutting, the resulting advantages include significant reduction of process time of up to 50%, higher tooth root strengths and higher load capacities compared to conventional manufacturing processes.