Tailored Forming of Hybrid Bevel Gears with Integrated Heat Treatment

authored by: Bernd Arno Behrens, Julian Diefenbach, Anna Chugreeva, Christoph Kahra, Sebastian Herbst, Florian Nürnberger
Abstract: “In recent years, multi-material designs of technical components have been gaining in importance. When combining different materials in a single component, it is possible to achieve high performance and extended functionality while simultaneously saving cost-intensive or rare materials. One promising approach to manufacture hybrid parts such as bi-metal gears is the utilization of the technology of tailored forming. This technology includes three main process steps: producing of bi-metal workpieces, forming and finishing. At the example of bevel gears, bi-metal preforms were produced by laser cladding of the martensitic steel X45CrSi9-3 on a cylindrical substrate made of the carbon steel C22.8 and formed to the final gear geometry by means of hot die forging. Subsequently, the hot bevel gears were directly quenched from hot-forming temperature by an air-water spray and self-tempered using the residual heat. To analyse the effect of each process step on the microstructure, specimens were extracted from cladded, forged and heat treated components and investigated by means of metallographic analysis and hardness measurements. The results demonstrate that cladded workpieces were successfully formed to complex toothed parts without any defects. The hot forming process has a positive impact on the welded layer and the interface zone by grain refinement and the associated improved mechanical properties. The required hardness values at the tooth flanks were achieved by the integrated heat treatment".
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Institute of Materials Science
Type: Conference article
Journal: Procedia Manufacturing
Volume: 47
Pages: 301-308
No. of pages: 8
ISSN: 2351-9789
Publication date: 2020
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Industrial and Manufacturing Engineering, Artificial Intelligence
Electronic version(s): https://doi.org/10.1016/j.promfg.2020.04.234 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{5df6b80bd29240f589567bdf58a0a4a8,
title = "Tailored Forming of Hybrid Bevel Gears with Integrated Heat Treatment",
abstract = "“In recent years, multi-material designs of technical components have been gaining in importance. When combining different materials in a single component, it is possible to achieve high performance and extended functionality while simultaneously saving cost-intensive or rare materials. One promising approach to manufacture hybrid parts such as bi-metal gears is the utilization of the technology of tailored forming. This technology includes three main process steps: producing of bi-metal workpieces, forming and finishing. At the example of bevel gears, bi-metal preforms were produced by laser cladding of the martensitic steel X45CrSi9-3 on a cylindrical substrate made of the carbon steel C22.8 and formed to the final gear geometry by means of hot die forging. Subsequently, the hot bevel gears were directly quenched from hot-forming temperature by an air-water spray and self-tempered using the residual heat. To analyse the effect of each process step on the microstructure, specimens were extracted from cladded, forged and heat treated components and investigated by means of metallographic analysis and hardness measurements. The results demonstrate that cladded workpieces were successfully formed to complex toothed parts without any defects. The hot forming process has a positive impact on the welded layer and the interface zone by grain refinement and the associated improved mechanical properties. The required hardness values at the tooth flanks were achieved by the integrated heat treatment{"}.",
keywords = "Air-water spray cooling, Bevel gear, Bi-metals, Hot die-forging, Process-integrated heat treatment, Tailored forming",
author = "Behrens, {Bernd Arno} and Julian Diefenbach and Anna Chugreeva and Christoph Kahra and Sebastian Herbst and Florian N{\"u}rnberger",
note = "Funding information: The pjroect “ Maschinenintegriertes optisches Messsystem zur Elektrodenpositionierung f{\"u}r das elektrothermische Pr{\"a}zisionsabtragen - OpToPS” o is supported by the Federal Ministry of Economics and Technology following a decision of the German Bundestag under grant number ZF4028028SY7. Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) - Project-ID 252662854 - SFB 1153. The results presented in this paper were obtained within the Collaborative Research Centre 1153 ?Process chain to produce hybrid high-performance components by Tailored Forming? in subproject A2 and B2. The authors would like to thank the subproject A4 for supplying cladded hybrid workpieces and the German Research Foundation (DFG) for the financial and organisational support of this project.; 23rd International Conference on Material Forming, ESAFORM 2020 ; Conference date: 04-05-2020",
year = "2020",
doi = "10.1016/j.promfg.2020.04.234",
language = "English",
volume = "47",
pages = "301--308",
journal = "Procedia Manufacturing",
issn = "2351-9789",
publisher = "Elsevier BV",
}