Energy-efficient production of gears with increased load carrying capacity through process-induced residual stresses during fineblanking

本研究项目的目的是利用SPP项目期间获得的知识，通过精冲生产适合工业应用中批量生产的真正的斜齿轮。除了将先前获得的结果转移到工业实践之外，这还包括进一步开发制造工艺以及获得更深入的工艺理解。另一个重要的目标是使设计或尺寸精冲齿轮在工业环境。与由至少三个工艺步骤（铣削、热处理和磨削）组成的传统制造相比，这种新工艺具有巨大的时间和成本节约潜力，并有可能显著减少二氧化碳排放。在计划的研究项目中，将系统地研究由几个精冲直齿轮组成的阶梯式齿轮所体现的小齿轮对。高工艺诱导的残余压应力的产生将转移到更薄的材料厚度和更高强度的材料上。除了由于高强度材料中较高的压残余应力而增加承载能力外，在刀具主动元件上使用涂层以降低切削表面的粗糙度，从而进一步增加齿轮的侧面承载能力。除了预测切割表面的粗糙度外，过程模拟还应提供有关预期残余应力状态的信息。除其他事项外，将要产生的数据库将用于为新开发的齿轮精冲工艺的工业应用制定指南。这些包括，例如，工艺边界条件，计算方程和齿轮设计图。此外，工业应用中精冲齿轮设计的标准建议将根据承载能力调查的结果制定。最后，对工艺限制内的经济方面进行调查和记录，例如制造成本的分解作为要生产的单位数量的函数。

The objective of this research project is to use the knowledge gained from the project periods of the SPP to produce a real helical gear by fineblanking that is suitable for series production in industrial applications. In addition to the transfer of previously obtained results into industrial practice, this also includes the further development of the manufacturing process as well as the acquisition of deeper process understanding. Another essential objective is to enable the design or dimensioning of fineblanked gears in an industrial environment. Compared to conventional manufacturing consisting of at least three process steps (milling, heat treatment and grinding), the novel process has enormous time and cost saving potential and the potential to significantly reduce CO2 emissions. In the planned research project, a pinion/wheel pairing embodied by stepped gears consisting of several fineblanked spur gears will be systematically investigated. The generation of high process-induced compressive residual stresses will be transferred to thinner material thicknesses and higher-strength materials. In addition to the increase in load carrying capacity due to higher compressive residual stresses in the higher-strength material, coatings are used on the tool active elements to reduce the roughness of the cut surface and thus further increase the flank load carrying capacity of the gears. In addition to predicting the roughness of the cut surface, a process simulation should also provide information on the residual stress state to be expected. The database to be generated will be used, among other things, to derive guidelines for the industrial application of the newly developed process for fineblanking of gears. These are to include, for example, process boundary conditions, calculation equations and gear design diagrams. Furthermore, standard proposals for the design of fineblanked gears in industrial applications will be drawn up on the basis of the findings from the load carrying capacity investigations. Finally, economic aspects within the process limits are investigated and documented, such as the breakdown of manufacturing costs as a function of the number of units to be produced.