Tailored Forming of Hybrid Bevel Gears with Integrated Heat Treatment

Behrens, Bernd Arno; Diefenbach, Julian; Chugreeva, Anna; Kahra, Christoph; Herbst, Sebastian; Nürnberger, Florian

doi:10.1016/j.promfg.2020.04.234

Cited by 11 publications

(6 citation statements)

References 13 publications

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“…The results of studies on the Tailored Forming process chain involving the materials or processes under investigation are presented in this section. Behrens et al investigated the production of hybrid bevel gears [20]. A LHWC process was used to apply a cladding of X45CrSi9-3 on a base cylinder of mild steel.…”

Section: Tailored Forming Process Chainmentioning

confidence: 99%

Investigation of the material combination 20MnCr5 and X45CrSi9-3 in the Tailored Forming of shafts with bearing seats

Budde

Biester

Merkel

et al. 2022

Prod. Eng. Res. Devel.

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The Tailored Forming process chain is used to manufacture hybrid components and consists of a joining process or Additive Manufacturing for various materials (e.g. deposition welding), subsequent hot forming, machining and heat treatment. In this way, components can be produced with materials adapted to the load case. For this paper, hybrid shafts are produced by deposition welding of a cladding made of X45CrSi9-3 onto a workpiece made from 20MnCr5. The hybrid shafts are then formed by means of cross-wedge rolling. It is investigated, how the thickness of the cladding and the type of cooling after hot forming (in air or in water) affect the properties of the cladding. The hybrid shafts are formed without layer separation. However, slight core loosening occurres in the area of the bearing seat due to the Mannesmann effect. The microhardness of the cladding is only slightly effected by the cooling strategy, while the microhardness of the base material is significantly higher in water cooled shafts. The microstructure of the cladding after both cooling strategies consists mainly of martensite. In the base material, air cooling results in a mainly ferritic microstructure with grains of ferrite-pearlite. Quenching in water results in a microstructure containing mainly martensite.

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Section: Tailored Forming Process Chainmentioning

confidence: 99%

Investigation of the material combination 20MnCr5 and X45CrSi9-3 in the Tailored Forming of shafts with bearing seats

Budde

Biester

Merkel

et al. 2022

Prod. Eng. Res. Devel.

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“…Behrens et al [16] also investigated welding for the production of straight bevel gears made from martensitic steel (X45CrSi9-3) on the tooth surface and carbon steel (C22.8) in the core. The preform materials were joined by laser hotwire cladding, machined and subsequently hot forged to the final geometry.…”

Section: Weldingmentioning

confidence: 99%

Review of recent developments in manufacturing lightweight multi-metal gears

Politis

Lin

2021

Prod. Eng. Res. Devel.

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This paper provides a review of recent developments in the manufacturing of lightweight multi-metal components, and in particular gears. The literature has shown that significant efforts have been made in manufacturing light gears and numerous technical challenges exist when designing for and manufacturing with dissimilar metals including challenges in heating technologies, mechanical performance, processing parameters, metal compatibility and the interface layer between adjacent materials, as well as difficulties in multi-metal simulations. Whilst the scope of multi-metal manufacturing is vast, the main concentration of this study is on the main stages of multi-metal gear production, and specifically on preform production, multi-metal heating, intermetallic bonding, and modelling of essential forming parameters. The effects of each of these methods as well as the numerous approaches studied in the literature are presented, with a recommendation being made as to a processing route that may lead to a robust multi-metal gear with minimal production line modifications to conventional steel gears.

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“…Behrens et al and Chugreeva et al manufactured hybrid bevel gears using a Tailored Forming process chain [3,4]. Shafts of low alloyed steel C22.8 with a protective cladding of heat treatable steel 41Cr4 were manufactured using a plasma transferred arc (PTA) welding process.…”

Section: Tailored Formingmentioning

confidence: 99%

Investigation of the influence of the forming process and finishing processes on the properties of the surface and subsurface of hybrid components

Budde

Prasanthan

Kruse

et al. 2021

Int J Adv Manuf Technol

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Due to the increased integration of functions, many components have to meet high and sometimes contradictory requirements. One way to solve this problem is Tailored Forming. Here, hybrid semi-finished products are manufactured by a joining or cladding process, which are then hot-formed and finished. For the design of hybrid components for a possible later industrial application, knowledge about properties of hybrid components is required. In this paper it is investigated how the respective process steps of the Tailored Forming process chain change the surface and subsurface properties of the applied cladding layer. For this purpose, shafts made of unalloyed steel are provided with a high-alloy austenitic steel X2CrNiMo19-12 cladding by laser hot-wire cladding. Subsequently, hot forming is carried out by cross-wedge rolling and the finishing by turning and deep rolling. After each process step, the subsurface properties of the cladding such as microstructure, hardness and residual stress state are examined. Thus, the influence of different process steps on the subsurface properties in the process chain of manufacturing hybrid shafts can be analyzed. This knowledge is necessary for the specific adjustment of defined properties for a required application behavior.

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Tailored Forming of Hybrid Bevel Gears with Integrated Heat Treatment

Cited by 11 publications

References 13 publications

Investigation of the material combination 20MnCr5 and X45CrSi9-3 in the Tailored Forming of shafts with bearing seats

Investigation of the material combination 20MnCr5 and X45CrSi9-3 in the Tailored Forming of shafts with bearing seats

Review of recent developments in manufacturing lightweight multi-metal gears

Investigation of the influence of the forming process and finishing processes on the properties of the surface and subsurface of hybrid components

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