SBIR Phase I: Development of Tools to Determine the Effect of Powder Metallurgy (P/M) Manufacturing Parameters on Fatigue of Highly Loaded Gears

SBIR 第一阶段：开发确定粉末冶金 (P/M) 制造参数对高负载齿轮疲劳影响的工具

• 批准号: 0510141
• 负责人: Gottfried Hoffmann
• 金额: --
• 依托单位: V-Tech International, Inc.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2005
• 资助国家: 美国
• 起止时间: 2005-07-01 至 2005-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0510141&HistoricalAwards=false
• 关键词: SBIR; Phase; Development; Tools; Determine

This Small Business Innovation Research (SBIR)Phase I project will develop and validate a tool to support a manufacturing innovation specifically, the powder metallurgy process to produce highly loaded automotive transmission gears. Powder metallurgy (P/M) processes offer an excellent combination of shape forming capability and material utilization, making the technology ideal for manufacturing highly loaded automotive transmission gears. Powder forging and recently developed surface densification processes combines shaping capability and nearly pore-free materials in critical areas in order to overcome strength limitations of the P/M materials. However, P/M processes have a high degree of variability, which makes optimization of process parameters imperative. This project will perform model testing of materials under rolling contact fatigue, which is one of the failure criteria of gears. The broader impacts (commercial significance) from this project will be on material science and processing. This project will provide the capability to study crack initiation and propagation under rolling contact fatigue conditions. This will lead to a new and better understanding of crack formation mechanisms and crack growth under constant and variable compressive stresses. It allows combining material properties obtained by classical methods such as micro-hardness, fracture mechanics, and microstructure analyses with rolling contact fatigue strength. It leads to a better understanding of the effect of process variables, heat treatment parameters, and material behavior under real operational conditions. The focus of this project is on P/M processes. However, the results will change the way gears and bearings of pore-free materials are being designed and manufactured. Improved gears and bearings will increase the efficiency of transmissions, therefore indirectly reducing energy consumption.

该小型企业创新研究（SBIR）第一阶段项目将开发和验证一种工具，以支持制造创新，特别是生产高负载汽车变速器齿轮的粉末冶金工艺。粉末冶金（P/M）工艺提供了成形能力和材料利用率的出色组合，使该技术成为制造高负载汽车变速器齿轮的理想选择。粉末锻造和最近开发的表面致密化工艺结合了成形能力和关键区域中几乎无孔的材料，以克服粉末冶金材料的强度限制。然而，粉末冶金工艺具有高度的可变性，这使得工艺参数的优化势在必行。本项目将进行材料在滚动接触疲劳下的模型试验，这是齿轮的失效标准之一。该项目的更广泛影响（商业意义）将是材料科学和加工。该项目将提供研究滚动接触疲劳条件下裂纹萌生和扩展的能力。这将导致一个新的和更好的理解裂纹形成机制和裂纹扩展下恒定和可变的压缩应力。它允许将通过经典方法获得的材料特性（如显微硬度、断裂力学和微观结构分析）与滚动接触疲劳强度相结合。它导致更好地了解工艺变量的影响，热处理参数，和材料行为下真实的操作条件。该项目的重点是P/M过程。然而，研究结果将改变无孔材料齿轮和轴承的设计和制造方式。改进的齿轮和轴承将提高传动效率，从而间接减少能源消耗。