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A Methodology for the Application of Virtual Evaluation Methods within the Design Process of Cold Forged Steel Pinions

Part of: Robust Design

Published online by Cambridge University Press:  26 July 2019

Andreas Rohrmoser ,
Björn Heling ,
Benjamin Schleich ,
Christoph Kiener ,
Hinnerk Hagenah ,
Sandro Wartzack  and
Marion Merklein
Andreas Rohrmoser*
Affiliation:
Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Manufactoring Technology;
Björn Heling
Affiliation:
Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Polymer Technology
Benjamin Schleich
Affiliation:
Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Polymer Technology
Christoph Kiener
Affiliation:
Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Manufactoring Technology;
Hinnerk Hagenah
Affiliation:
Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Manufactoring Technology;
Sandro Wartzack
Affiliation:
Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Polymer Technology
Marion Merklein
Affiliation:
Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Manufactoring Technology;
*
Contact: Rohrmoser, Andreas, Friedrich-Alexander-Universität Erlangen-Nürnberg Institute of Manufacturing Technology, Germany, [email protected]

Abstract

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Gears are essential machine elements in the drivetrain and transmission technology. The operational behaviour of a gear pairing is influenced by the design of the gear kinematics as well as the component properties. With regard to an improvement of performance and service life, the targeted modification of tooth geometry and component properties offers a promising approach. Thus, the achievable geometric and mechanical component properties are influenced by the manufacturing process, which must be taken into account in the design process. The application of virtual evaluation methods is suitable for this purpose. For the manufacturing of steel gears, cold forging provides the potential of achieving beneficial mechanical properties in a highly productive process. Major challenges for the industrial application are the short service life of the cost- intensive tools and the low geometric accuracy in comparison to machining processes. Within this study the design of the tooth geometry as well as the associated forming tool are investigated. The aim is to derive recommendations regarding an optimization of the resulting component properties and operational behaviour.

Keywords

Design processSimulationNumerical methodsGear designManufacturing processes
Type
Article
Information
Proceedings of the Design Society: International Conference on Engineering Design , Volume 1 , Issue 1 , July 2019 , pp. 3451 - 3460
Creative Commons
Creative Common License - CCCreative Common License - BYCreative Common License - NCCreative Common License - ND
This is an Open Access article, distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives licence (http://creativecommons.org/licenses/by-nc-nd/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is unaltered and is properly cited. The written permission of Cambridge University Press must be obtained for commercial re-use or in order to create a derivative work.
Copyright
© The Author(s) 2019

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