FE-based Layer Design of Deposition-Welded Semi-finished Parts for the Production of Hybrid Bevel Gear

authored by: Bernd Arno Behrens, Johanna Uhe, Hendrik Wester, Tim Matthias, Christoph Büdenbender
Abstract: Multi-material solutions offer numerous benefits as they, in contrary to conventional monolithic parts, represent tailor-made hybrid components with enhanced application-optimisation properties. The use of hybrid semi-finished products is the approach to apply the right material in the right place. This procedure of manufacturing components helps to reduce costs and avoids the waste of resources. Within this paper, a process route is presented, which can be used to produce a hybrid bevel gear by means of tailored forming technology. For the bevel gear, C22.8 was used as base material. The wheel body was designed with 41Cr4 and X45CrSi9-3. The semi-finished product was manufactured by means of deposition welding. The resulting geometry of the semi-finished product is a cylindrical body with two thin outer layers. This article focuses on the numerical investigation of the required layer thickness, so that on the one hand a material distribution after the forming process can be adjusted in order to guarantee the longest possible service life and on the other hand a stable forming process without cracks of the surface of the layers. Due to locally different material properties of the semi-finished product, uncommon material flow occurs. Furthermore, the deposition-welded material has different flow properties than conventional material. Therefore, a material characterisation by means of upsetting test was carried out for the 41Cr4 and X45CrSi9-3 in the deposition-welded status and was compared to conventional material. The initial thickness of the deposition-welded layers was designed with the aid of numerical simulation. The initial geometry of the layers was designed in such a way that the tooth body is completely filled after forming with an optimal use of material.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Conference article
Journal: Procedia Manufacturing
Volume: 47
Pages: 309-314
No. of pages: 6
ISSN: 2351-9789
Publication date: 26.04.2020
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.2020.04.235 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{f68fdf3cba6641778f763c19733f4d6f,
title = "FE-based Layer Design of Deposition-Welded Semi-finished Parts for the Production of Hybrid Bevel Gear",
abstract = "Multi-material solutions offer numerous benefits as they, in contrary to conventional monolithic parts, represent tailor-made hybrid components with enhanced application-optimisation properties. The use of hybrid semi-finished products is the approach to apply the right material in the right place. This procedure of manufacturing components helps to reduce costs and avoids the waste of resources. Within this paper, a process route is presented, which can be used to produce a hybrid bevel gear by means of tailored forming technology. For the bevel gear, C22.8 was used as base material. The wheel body was designed with 41Cr4 and X45CrSi9-3. The semi-finished product was manufactured by means of deposition welding. The resulting geometry of the semi-finished product is a cylindrical body with two thin outer layers. This article focuses on the numerical investigation of the required layer thickness, so that on the one hand a material distribution after the forming process can be adjusted in order to guarantee the longest possible service life and on the other hand a stable forming process without cracks of the surface of the layers. Due to locally different material properties of the semi-finished product, uncommon material flow occurs. Furthermore, the deposition-welded material has different flow properties than conventional material. Therefore, a material characterisation by means of upsetting test was carried out for the 41Cr4 and X45CrSi9-3 in the deposition-welded status and was compared to conventional material. The initial thickness of the deposition-welded layers was designed with the aid of numerical simulation. The initial geometry of the layers was designed in such a way that the tooth body is completely filled after forming with an optimal use of material.",
keywords = "Materical characterisation, Numerial material flow investigation, Tailored forming",
author = "Behrens, {Bernd Arno} and Johanna Uhe and Hendrik Wester and Tim Matthias and Christoph B{\"u}denbender",
note = "Funding Information: 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 the subproject C1. The authors would like to thank the German Research Foundation (DFG / 252662854) for the financial and organisation support of this project. In addition, the authors would like to thank subproject A4 for the provision of semi-finished products for the material characterisation. ; 23rd International Conference on Material Forming, ESAFORM 2020 ; Conference date: 04-05-2020",
year = "2020",
month = apr,
day = "26",
doi = "10.1016/j.promfg.2020.04.235",
language = "English",
volume = "47",
pages = "309--314",
journal = "Procedia Manufacturing",
issn = "2351-9789",
publisher = "Elsevier BV",
}