SUNConferences, COMA '13

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Rolling Processes for Gear Manufacturing – Potentials and Challenges
Matthias Milbrandt, Mike Lahl, Udo Hellfritzsch, Andreas Sterzing, Reimund Neugebauer

Last modified: 2013-08-21


Due to the increasing demands concerning resource-efficient manufacturing processes, the aspect of material savings becomes more and more important. In comparison with cutting operations, the use of forming processes offers the chance to achieve significant saving effects. In the field of the automotive powertrain, the manufacturing of helical gears by rolling processes is an outstanding example.

In comparison with machining processes, the following benefits can be identified:

- no chip generation, therefore no material loss,

- reduced process time (up to 50 %),

- higher surface qualities,

- improved load capacity based on contour-related,  uninterrupted fibre orientation,

- reduced distortion by forming-related generation of residual stresses.

Based on extensive investigations in the last years, helical gears with tooth heights higher than 12 mm and with a gearing quality of 9 have been realized.  

The presentation will give an overview about the research activities of the Fraunhofer IWU in this field. Main aspects will be:

- process basics of gear rolling,

- illustration of today’s process limits, that means realizable gear geometries and qualities,

- methods of extension of these limits, especially by optimized tool and process design.

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