Identification of process parameters affecting distortion of disks for gear manufacture Part I: casting, forming and machining

Clausen, B.; Frerichs, F.; Kohlhoff, Tim; Lübben, Th.; Prinz, C.; Rentsch, R.; Sölter, Jens; Surm, H.; Stöbener, Dirk; Klein, Dieter

doi:10.1002/mawe.200900459

Cited by 19 publications

(27 citation statements)

References 8 publications

(4 reference statements)

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“…Both approaches led to a reduced scatter of the change of dishing as well (for more details [4]. However the influences of the material properties and other processes of the manufacturing chain are being analyzed and have been presented elsewhere [2,6].…”

Section: Materials Flow and Distortion Of The Gear Wheel Blanksmentioning

confidence: 99%

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Parameters of distortion in forging gear wheel blanks

Rentsch

2012

Materialwissenschaft Werkst

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The gear wheel manufacture is one of the key technologies for power train systems and in automotive industry. These complex high performance parts require stable processes and narrow tolerances in order to control the manufacturing costs. Experimental analyses show that the material flow in disk-like gear wheel blanks made of 20MnCr5 can vary significantly. This is of significance as a correlation between the dishing after case-hardening of the gear wheel blanks and the material flow was found. Besides experimental findings, finite element (FE) analyses of the influence of process parameters and perturbations on the distortion of forged gear wheel blanks have been carried out. A temperature gradient over the height of the workpiece is assumed to be largely responsible for the observed material flow variations and the related dishing of the forged gear wheel blanks.

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Section: Materials Flow and Distortion Of The Gear Wheel Blanksmentioning

confidence: 99%

“…By analysing the distortion behaviour of disks for the manufacture of gears, Clausen et al [2] identified several process parameters as highly significant regarding shape changes. On basis of a design of experiment (DoE), measurement data of the disks faces, their center hole and circumferences were analysed by means of Fourier series.…”

Section: Introductionmentioning

confidence: 99%

Parameters of distortion in forging gear wheel blanks

Rentsch

2012

Materialwissenschaft Werkst

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“…The distortion is not only restricted to the teeth. Also, the gear's base body can distort during the manufacturing process [1,2].…”

Section: Introductionmentioning

confidence: 99%

Areal parameters for the characterisation of gear distortions

Stöbener

Freyberg

Fuhrmann

et al. 2012

Materialwissenschaft Werkst

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Gear distortion is influenced by several effects which might originate in various steps of the entire production chain. To understand the distortion mechanisms including interactions between different influencing parameters, a system approach for the whole production process is required. As distortion is not constrained to the toothing but also effects the gear's base body, an extended measuring strategy (compared to the standard) has been devised. Based on this strategy, an areal evaluation has been developed and new quality parameters describing the deviations of the whole gear and of each tooth have been defined. In contrast to the standard evaluation, the new quality parameters consider the relationship between different measured lines. This offers the possibility to determine the influences of the base body deviations on the toothing distortion and to separate them from the intrinsic toothing deviation. This paper describes the developed strategies and methods and compares them with the standard inspection process.Keywords: gear / distortion / areal evaluation / measurement strategy / cmm / Der Verzug von Zylinderrädern wird durch verschiedene Effekte beeinflusst, die in unterschiedlichen Teilen der Fertigungskette auftreten können. Um die Verzugsmechanismen inklusive der Wechselwirkungen zwischen den einzelnen Einflussgrößen vollständig zu verstehen, ist ein Systemansatz für den gesamten Fertigungsprozess erforderlich. Da der Verzug nicht nur auf die Verzahnung beschränkt ist, sondern am gesamten Zylinderradkörper auftreten kann, ist (verglichen mit dem Standard) eine aufwändige Messstrategie für Zylinderräder entworfen worden. Basierend auf dieser Strategie konnte eine flächenhafte Auswertung inklusive neuer Qualitätspara-metern entwickelt werden, welche sowohl die Formabweichungen des gesamten Zylinderrades als auch die der einzelnen Zähne beschreiben. Die Auswertung berücksichtigt im Gegensatz zum Standard-Verfahren die Beziehungen zwischen den einzelnen gemessenen Linien. Damit ergibt sich die Möglichkeit, die Einflüsse der Grundkörperverformungen auf den Verzahnungsverzug zu bestimmen und sie von denen der Verzahnung zu separieren. Der Artikel beschreibt die entwikkelten Strategien und Methoden und vergleicht sie mit dem standardisierten Mess-und Auswerteprozess.

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“…For this reason, it was decided to make the samples in the form of rings with a through hole. The formation of distortion is a very complex problem, so the generalization of the problem will only be possible using models with simple geometry [3][4]. Figure 1 shows the geometry of ring prototypes for distortion testing.…”

Section: Geometry Selection For Distortion Testingmentioning

confidence: 99%

“…The use of a particular element will determine the conditions of the carried thermal processes [1][2][3].…”

Section: Introductionmentioning

confidence: 99%

Study of Distortion on the Example of the Rings from Ductile Iron and Cast Steel

Łukasik¹,

Nawrocki²,

Misiak³

et al. 2017

Archives of Foundry Engineering

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The paper attempts to analyze distortions of cast iron and cast steel rings, after heat treatment cycles. The factors influencing distortion are: chemical composition of material, sample geometry, manufacturing process, hardenability, temperature and heat treatment method. Standard distortion tests are performed on C-ring samples. We selected a ring-model, which approximate the actual part, so that findings apply to gear rings. Because distortion depends on so many variables, this study followed strictly defined procedures. The research was started by specifying the appropriate geometry of the samples. Then, the heat treatment was conducted and samples were measured again. The obtained results allow to determine the value of the resulting distortion and their admissibility. The research will be used to evaluate the possibility of using the material to produce parts of equipment operated under extreme load conditions.

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Identification of process parameters affecting distortion of disks for gear manufacture Part I: casting, forming and machining

Cited by 19 publications

References 8 publications

Parameters of distortion in forging gear wheel blanks

Parameters of distortion in forging gear wheel blanks

Areal parameters for the characterisation of gear distortions

Study of Distortion on the Example of the Rings from Ductile Iron and Cast Steel

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