Berücksichtigung funktionsrelevanter Gestaltabweichungen bei der Auslegung von Umformprozessen zur Herstellung von Stirnrädern mit Sonderverzahnung durch Fließpressen
Start: 1. April 2016
Ende: 31. March 2023
The subproject TP4 is part of the DFG research group 2271 - process-oriented tolerance management with virtual validation methods.
In order to achieve an integrated tolerance management, it is necessary to consider not just the process-related causes of geometric component deviations but also the deviations resulting from operation. The aim of the subproject is to identify variables influencing the operational behavior of extruded gears in the material pairing metal-plastic and to derive functional relationships between the process-related component properties and the resulting wear behavior of the pairing. Based on these findings, an operation-optimized design of the extrusion process for the production of ready-to-use gears is to be carried out and compliance with the function-relevant tolerances over the service life is to be ensured. Within the framework of the research group's overall objectives, an important contribution is made to accomplish a holistic approach within process-orientated tolerance management.
The project is based on the findings of the first funding period. During this period, the focus was on the identification of influencing variables and process-related fluctuations and its effects on the geometric accuracy and mechanical properties of steel gears produced by full forward extrusion. For this purpose, the impact extrusion process was mapped using the finite element method and a reference process was designed. The FEM model has been validated by forming experiments. The validated model was then used to identify influencing variables on the component and process side. The effects of process-related fluctuations on the resulting geometric and mechanical component properties were investigated by further forming tests. From the results, a process window was derived to ensure compliance with the functionally relevant tolerances.
In the second funding period, the effects of the process-related geometric, mechanical and tribological properties of extruded gears on geometric deviations as a result of the characteristic wear behavior of the metal-plastic material pairing during operation will be investigated. The resulting decrease in tooth width limits the adherence to the tolerances as well as the lifetime of the pairing due to tooth wear. The investigations regarding the wear behavior of the material pairing metal-plastic of the first funding period show that the properties of the metallic partner have a significant influence on the wear of both gears. Against this background, the choice of the gear material and the specific adaptation of the application-relevant component properties of the gearing within the extrusion process offer potential. Within the framework of the sub-project, the essential wear mechanisms within the material pairing are identified and the application-relevant component properties of the metallic gearing are determined on a transmission test bench. Finally, recommendations regarding the operationally optimized design of extrusion processes are derived and verified.
Influence of metal gear tooth geometry on load and wear within metal-polymer gear pairs
In: Applied Sciences 12 (2022), Article No.: 270
DOI: 10.3390/app12010270 , , , , , :
Influence of Metal Flank Hardness of Machined and Cold Forged Gears on Wear within a Metal-Polyamide Gear Pair and Targeted Process Adaptation
In: Journal of Materials Engineering and Performance (2022)
DOI: 10.1007/s11665-022-07251-z , :
Influence of production process-induced surface topologies at varying roughness depths on the tribological properties of polyamide steel contact
In: Journal of Polymer Engineering (2022)
DOI: 10.1515/polyeng-2022-0231 , , , , , , :
Adapted tool design for the cold forging of gears from non-ferrous and light metals
In: International Journal of Advanced Manufacturing Technology (2021)
DOI: 10.1007/s00170-020-06449-6 , , :
Influence of the forming induced hardening on the wear behavior of aluminum gears within a metal-plastic material pairing and targeted adaption
49th SME North American Manufacturing Research Conference, NAMRC 2021 (Cincinnati, OH, 21. June 2021 - 25. June 2021)
In: Livan Fratini, Ihab Ragai (ed.): Procedia Manufacturing 2021
DOI: 10.1016/j.promfg.2021.06.078 , , :
Ausgewählte Einflussgrößen auf die erzielbaren Verzahnungstoleranzen beim Kaltfließpressen.
In: Sandro Wartzack (ed.): Summer School Toleranzmanagement - Beiträge zur 4. Summer School - September 2020, Erlangen: 2020 , , , , :
Verschleißmodellierung am Beispiel einer Polyamid-Stahl-Getriebepaarung für das prozessorientierte Toleranzmanagement
Summer School Toleranzmanagement (Erlangen, 28. September 2020 - 28. September 2020)
In: Sandro Wartzack (ed.): Beiträge zur 4. Summer School 2020 , , , , :
A methodology for the application of virtual evaluation methods within the design process of cold forged steel pinions
22nd International Conference on Engineering Design (, 5. August 2019 - 9. August 2019)
In: Proceedings of the 22nd International Conference on Engineering Design (ICED19), Delft, The Netherlands: 2019
DOI: 10.1017/dsi.2019.352 , , , , , , :
Einsatz numerischer Analysetools bei der Auslegung und Herstellung kaltfließgepresster Stahlzahnräder
In: Konstruktion (2019), p. 85-90
ISSN: 0720-5953 , , , :
Influence of tribological conditions on application relevant component properties of cold forged gears
In: Production Engineering (2019)
DOI: 10.1007/s11740-019-00909-z , , , :
Untersuchung des Einsatzverhaltens kaltfließgepresster Zahnräder
34. Jahrestreffen der Kaltmassivumformer (Düsseldorf, 27. February 2019 - 28. February 2019)
In: VDI Wissensforum GmbH (ed.): 34. Jahrestreffen der Kaltmassivumformer 2019 , , , :