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Helical gear manufacturing by net-shape-technology-potentials and challenges

: Drossel, Welf-Guntram

Hancic, A.:
ICIT&MPT 2014, 9th International Conference on Industrial Tools and Material Processing Technologies : 9th-11th April 2014, Ljubljana, Slovenia
Celje: TECOS, 2014
ISBN: 978-961-6692-03-8
International Conference on Industrial Tools and Material Processing Technologies (ICIT&MPT) <9, 2014, Ljubljana>
Fraunhofer IWU ()
gear rolling; finite element method; gear qualities

The need to adopt an even more efficient approach to handling existing resources is becoming more and more a public duty in politics, economy and research. At the same time this raises the question of what options are available to companies in the manufacturing industries, the OEMs and, in particular, supplier companies of the automotive industry as regards reducing costs as well as minimising their consumption of resources and reducing emissions by using more efficient technologies and production systems. In the field of helical gear manufacturing, the application of net-shape technology like gear rolling as forming process offers the chance to achieve significant saving effects. In comparison with machining processes, the following benefits can be identified:
- No chip generation, therefore significantly optimized material use,
- Reduced process time,
- Higher surface qualities,
- Improved load capacity based on contour-related, uninterrupted fibre orientation and work hardening,
- Reduced distortion by forming-related generation of residual stresses.
The paper will mainly give an overview about the state-of-research in the field of gear manufacturing by forming process. It will focus on activities of the Fraunhofer Institute for Machine Tools and Forming Technology in gear rolling.