Determination of process limits for the reconditioning of worn-out gear wheels by precision postforming at elevated temperatures

在计划的项目范围内，应确定在高温下精密后成形修复封闭模具内磨损齿轮的工艺极限。在创新工艺链上的齿轮制造中可以实现对钢铁生产污染减少的贡献。磨损的齿轮应在其成熟后通过精密后压和随后的硬精加工进行另一个生命周期的使用。从钢铁回收到齿轮回收的变化允许替代能源和资源消耗的钢铁生产，也可以替代原锻件的个别工艺步骤。本研究项目的目的是确定磨损齿轮精密后成形的变形极限。为此在展开时发生齿轮失效的原因，如磨损、点蚀和齿断裂都会产生。随后，在考虑变形工艺参数的情况下，在封闭模具中进行高温精密后成形。此外，还研究了后成形前对磨损齿轮不均匀加热对材料流动和成形极限的影响。本研究项目是在面向工艺的基础研究的基础上，分析在闭式模具成形技术中，磨损的齿轮是否可以回收。

Within the planned project, the process limits for reconditioning of worn-out gears in a closed die by precision postforming at elevated temperatures shall be determined.A contribution to the reduction caused by the steel production pollution can be achieved in the manufacture of gears on an innovative process chain. Worn-out gears should be used after their maturity by precision postforming and a subsequent hard finishing for another life cycle. The change from steel recycling toward the gear recycling allows the substitution of energy- and resource-consuming production of steel and also the individual process steps of the raw forging.The aim of this research project is to determine deformation limits for precision postforming of worn-out gears. For this to occur in the deployment causes of failure of gears, such as wear, pitting and tooth fracture will be produced. Subsequently, the precision postforming at elevated temperatures in the closed die have to be carried out under consideration deformation process parameters. Furthermore, the influence of a non-homogeneous heating of the worn-out gears before the postforming on the flow of material and the forming limits are examined. This research project is to be analysed on the basis of process-oriented basic research, whether worn-out gears can be recycled in the closed die forming technology.