EP1890831B1 - Procédé de fabriquer un endentement de matérieau fritté - Google Patents

Procédé de fabriquer un endentement de matérieau fritté Download PDF

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Publication number
EP1890831B1
EP1890831B1 EP06754213.4A EP06754213A EP1890831B1 EP 1890831 B1 EP1890831 B1 EP 1890831B1 EP 06754213 A EP06754213 A EP 06754213A EP 1890831 B1 EP1890831 B1 EP 1890831B1
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EP
European Patent Office
Prior art keywords
toothing
tooth
flank
preform
oversize
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EP06754213.4A
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German (de)
English (en)
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EP1890831A2 (fr
Inventor
Gerhard Kotthoff
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GKN Sinter Metals Holding GmbH
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GKN Sinter Metals Holding GmbH
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Publication of EP1890831A2 publication Critical patent/EP1890831A2/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H5/00—Making gear wheels, racks, spline shafts or worms
    • B21H5/02—Making gear wheels, racks, spline shafts or worms with cylindrical outline, e.g. by means of die rolls
    • B21H5/022—Finishing gear teeth with cylindrical outline, e.g. burnishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/08—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of toothed articles, e.g. gear wheels; of cam discs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/16—Both compacting and sintering in successive or repeated steps
    • B22F3/164—Partial deformation or calibration
    • B22F2003/166—Surface calibration, blasting, burnishing, sizing, coining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/241—Chemical after-treatment on the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/248—Thermal after-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49462—Gear making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49462—Gear making
    • Y10T29/49467—Gear shaping
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49462—Gear making
    • Y10T29/49467—Gear shaping
    • Y10T29/49478—Gear blank making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49462—Gear making
    • Y10T29/49467—Gear shaping
    • Y10T29/4948—Gear shaping with specific gear material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T409/00—Gear cutting, milling, or planing
    • Y10T409/10—Gear cutting
    • Y10T409/100159—Gear cutting with regulation of operation by use of templet, card, or other replaceable information supply
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T409/00—Gear cutting, milling, or planing
    • Y10T409/10—Gear cutting
    • Y10T409/101431—Gear tooth shape generating

Definitions

  • the present invention relates to a method for producing a toothing from sintered material.
  • Sintered gear elements such as gears made by powder metallurgy are used in some areas.
  • creating a suitable production of sintered components due to the powder, its behavior and its properties with regard to some technical fields of application compared to conventional solid materials creates problems.
  • From the GB 2 250 227 A shows a device for producing a gearwheel starting from a preform.
  • the object of the present invention is to enable an improvement in the production of a toothing from sintered material.
  • a preform can be used for the production of a toothing from sintered material, the preform having a negative oversize.
  • the negative oversize is preferably arranged at least on one flank of a tooth of the toothing.
  • the negative oversize can run asymmetrically along the flank.
  • a further development provides that a negative oversize is to be carried out on each flank of a tooth.
  • a tooth at the same height has a first negative oversize on a first flank and a second negative oversize on a second flank, the first and second flanks being asymmetrical to one another.
  • the negative oversize is preferably arranged between a head region of the tooth and an oversize on a flank of the tooth.
  • the negative oversize can be arranged in a corner region of the tooth base.
  • a method for producing a toothing from a sintered material wherein a preform is assigned at least one negative oversize, determined by means of iterative calculation, which is at least partially filled by displacement of the sintered material when the toothing is surface-densified.
  • a measurement material adjacent to the negative measurement is preferably displaced into the negative measurement.
  • the preform can be surface-compacted into the desired final shape, with optional hardening and / or surface finishing. This can be done before or after surface compaction. Honing and grinding can be considered as finishing.
  • the negative oversize is preferably designed using an iterative calculation, in which a simulation of the surface compaction on the preform determines whether the shape of the adjacent oversize is designed such that d the negative oversize can be smoothed towards the desired final contour.
  • a machine is provided for the calculation and / or for the execution of a surface compression of a toothing, wherein a calculated kinematics can be included, by means of which a negative allowance on a flank of the toothing can be smoothed to a desired final contour via the surface compression.
  • a preform of the toothing element is produced with a locally selective allowance based on a final dimension of the toothing element and rolled to the final dimension by means of at least one rolling tool, the Gear element is compacted locally at least in the region of at least one flank and / or a foot of a tooth of the tooth element to produce a compressed edge layer on a surface.
  • a gear element is, for example, a gear, a rack, a cam, a P-rotor, a ring gear, a chain gear or the like.
  • the compacted sintered material is produced in particular using powder metallurgy processes.
  • a metal powder is sintered under pressure in connection with a heat treatment.
  • metal powder for example, is injection molded in connection with plastic and, in particular, is sintered under a pressure, preferably with a heat treatment.
  • a sintered shape is used which has at least almost the final dimension of the toothing element to be produced.
  • the workpiece resulting directly from the sintering process is preferably used as the preform.
  • at least one further surface processing step can also be followed.
  • the preform has an oversize, which is to be understood as the difference to a final dimension, the difference being preferably defined pointwise perpendicular to the surface.
  • a rolling tool for example, a roller is used which is equipped with a toothing which can be brought into engagement with the toothing of the toothing element.
  • a rolling tool is in particular under pressure on a Rolled surface of the gear element.
  • two or more such rolling tools are preferably used simultaneously.
  • a gear wheel to be produced can be arranged centrally between two rolling tools.
  • first rolling tool under a first pressure, essentially for rough contour rolling, and then a second rolling tool under a second pressure to achieve the surface compaction to be set in a targeted manner.
  • the locally selective oversize is in particular dimensioned such that the toothing element is compacted in a locally varying manner on a surface at least in the area of at least one flank or additionally of a foot of a tooth of the toothing element.
  • a full density is preferably achieved within the compressed outer layer, the full density preferably being understood in relation to a density of a comparable powder-forged tooth.
  • a preform made of a sintered material in a core has a density of at least 6.8 d / cm 3 , preferably of at least 7.1 g / cm 3 and in particular of at least 7.3 g / cm 3 .
  • the preform has, for example, a density of at least 7.7 g / cm 3 , preferably of at least 7.8 g / cm 3 , which corresponds to the density of a powder-forged preform made of the same material.
  • a strength curve that is suitable for the stress is particularly advantageously achieved.
  • a highly stressable sintered toothing is preferably provided.
  • the density profile can have a greater degree of density over a larger area, in particular in the areas subject to higher stress, in comparison to immediately adjacent areas of lower load.
  • the differently compacted edge layer is also produced over a different allowance along a flank and / or tooth base of the preform.
  • a depth of the compressed edge layer viewed perpendicular to the surface, has a maximum density at approximately the location of a maximum stress. This can, for example, be halfway up the tooth and decrease continuously to zero in relation to the tooth head and the tooth base.
  • a particularly high compression in the sintered material is set in a range between 20% and 30%, in particular between 23% and 25%, below the rolling circle.
  • other courses can also be provided.
  • a force profile on a tooth flank of the toothing element is taken into account in its intended use.
  • the forces occurring on the teeth of a gearwheel in a transmission are used and the resulting comparison stress curves below the surface are used. This procedure is also possible with other gears.
  • an oversize on a first flank of the tooth is chosen differently than on a second flank of the tooth.
  • a direction of force transmission is taken into account in the intended use of a toothing element.
  • this takes into account the fact that, depending on a direction of rotation in the direction of rotation, different forces occur on the tooth flanks than against the direction of rotation.
  • a different compression due to a direction of rotation of a rolling tool can be compensated for.
  • the oversizes are preferably chosen such that after a compression process, an identical compression profile results along the first and the second tooth flank.
  • a locally compressed surface layer is also sought in these areas. It is particularly expedient if an asymmetrical oversize is selected in a tooth base. For example, a left tooth root area has a different compression depth than a right tooth root. In particular, between two Teeth a preferably continuous variation of a depth of an edge layer can be provided by a corresponding variation of the allowance.
  • a different, in particular asymmetrical dimension is preferably provided not only with respect to one flank, but preferably with respect to two flanks lying opposite one another.
  • a different dimension is provided in the tooth base, which is preferably asymmetrical. Tooth flanks and tooth feet of a toothing can each be asymmetrical.
  • the oversize is not only to be understood as the provision of additional material. Rather, this also includes an undersize. This is to be understood to mean that less sintered material is provided in a zone than would have to be provided in relation to an end contour after a processing step.
  • the undersize determined ensures, for example, that no undesired elevations occur when sintered material is displaced.
  • the undersize therefore represents an area of a preform with a toothing that is to be filled in by displacement of sintered material.
  • the pressure angle of the one flank of the tooth can thus deviate by at least 15% from the pressure angle of the other flank of the tooth.
  • a density that is 2% to at least 15% higher than on a second flank of the tooth is generated at the same height.
  • a density is preferably achieved on the first flank of the tooth which corresponds at least approximately to the density achieved for a powder-forged toothing element, whereas the second flank has a lower density.
  • a density in a range between 7.2 g / cm 3 and 7.7 g / cm 3 is set an edge, while in the corresponding region of the second flank has a density between 7.5 g / cm 3 and 7.82 g / cm 3 is set.
  • this takes into account, for example, different loads on the two tooth flanks that are dependent on the direction of rotation.
  • a requirement-oriented elasticity and hardness curve is preferably achieved. This furthermore preferably reduces noise development, for example in a transmission.
  • a local oversize on a first flank of the tooth is chosen to be at least 10% larger than an oversize on a second flank of the tooth at the same height.
  • an identical compression profile is achieved on the first and the second tooth flank due to different pressurization during compression depending on the direction of rotation.
  • a different compression profile is achieved on the first and the second tooth flank.
  • different maximum densities, their depths as well as their location in relation to the height of the toothing can be set specifically.
  • an amount of a maximum local oversize is at least 15 ⁇ m, preferably at least 100 ⁇ m and particularly preferably at least 400 ⁇ m. If the density of the preform is in a range between 7.2 g / cm 3 and 7.5 g / cm 3 , a maximum allowance between 20 and 150 ⁇ m is preferably provided. If the density of the preform is between 6.7 g / cm 3 and 7.2 g / cm 3 , a maximum allowance between 50 ⁇ m and 500 ⁇ m is preferably used.
  • An oversize can also be negative locally, taking into account, for example, a lateral redistribution of material. Lateral redistribution can occur by flowing material as a result of a rolling process.
  • an at least locally negative oversize can be provided, which is locally below the final dimension.
  • the negative oversize is preferably at most 100 microns.
  • the negative oversize is at most less than 50 ⁇ m and in particular less than 20 ⁇ m.
  • the maximum negative oversize is in a range between 100 ⁇ m and 20 ⁇ m.
  • a compression is preferably achieved which reaches a depth of between 1 mm and 1.5 mm at least in a region of a tooth flank of the toothing.
  • the compression in the tooth base can be lower.
  • the maximum depth of compression of a tooth flank is at least 6 times greater than a maximum depth of compression in a region of the associated tooth base. This allows the toothing to have sufficient strength on the one hand, but on the other hand also maintain a certain deformability. This prevents tooth breakage.
  • the preform and the rolling tool are rolled onto one another until a final shaping movement is generated between the toothing element produced thereby and the rolling tool.
  • This is used, for example, to manufacture gear wheels that are in engagement with one another.
  • Preference is given to the rolling tool during the rolling process a distance between the rolling tool and preform is reduced. Accordingly, a rolling pressure is set or adjusted in particular.
  • path control can also be implemented on the machine.
  • a pure path control can also take place in one section of the production and a pure force control in another section of the production. These can also alternate several times.
  • a cycloidal and / or involute toothing is created between the preform and the rolling tool by means of the rolling movement.
  • gear elements in the sense of gear wheels other gear elements can also be produced.
  • a cam is produced as the toothing element.
  • a cam can be produced such as is used, for example, for the mechanical actuation of an adjusting device, for example for adjusting a valve or the like.
  • a locally varied compression of an edge layer on a flank of a cam preferably provides an improved strength profile with less susceptibility to wear.
  • a further improvement in surface hardening can be achieved in particular in that the method for producing an at least partially surface-compressed metal toothing element comprises a thermal and / or chemical surface hardening process.
  • case hardening for example, is used as the thermal and / or chemical hardening process.
  • tension is preferably reduced.
  • a carbonitriding process is used.
  • a nitriding or nitrocaborating process as well as a boriding process can be used.
  • a reduction in tension is also achieved in these processes in connection with a heat treatment.
  • the hardening can also be influenced by adjusting the prevailing pressure. For example, a vacuum can be set, especially when case hardening is carried out. There is also the possibility of induction hardening.
  • the hardening is carried out only partially, for example only in the area of the toothing.
  • a method for producing an at least partially surface-hardened metal toothing element comprises the steps "cold or hot pressing, sintering, dimension and surface compaction rolls and case hardening".
  • a metal powder is first cold-pressed in a mold which has at least approximately the final dimension of the toothing element to be produced.
  • the sintering process takes place under the action of heat with or without the action of pressure.
  • the dimensional and surface compaction is then preferably carried out by means of rollers.
  • dimension and surface compaction rolling is preferably carried out simultaneously using at least two rolling tools. This can be followed by hardening, in particular case hardening, which enables the surface to be hardened further.
  • a further embodiment of the invention provides that surface compaction can be carried out using a wide variety of methods.
  • One embodiment in particular provides that the surface compaction is carried out with a different method in a first area than in a second, different area.
  • Shot blasting, shot peening, compaction by means of a ball, by means of a roller or by means of another rotatable body, by means of tooth-shaped tools, in particular rolling tools and the like, can be used as methods. These methods are also suitable, each separately, to allow the necessary surface compaction.
  • the tooth base is not compressed at all or only slightly with a tool that also compresses the tooth flank. It is possible to compress the surface in one section to such an extent that only the pores on the surface are closed.
  • the tooth base can then be processed with another tool or surface compaction method.
  • a different surface compaction along the tooth flank can be achieved compared to the tooth base.
  • different surface qualities can be set in this way, for example with regard to the roughness.
  • the maximum surface recess may also be different due to the different techniques.
  • the entire workpiece with the toothing receives a surface compaction, for example during surface blasting.
  • aluminum-containing sintered materials or other oxide-forming sintered materials can also be processed, since the surface compaction can also make it possible to remove an oxide layer.
  • a preform is used for a method for producing an at least partially surface-hardened metal toothing element, which has a compressed sintered material, a first and a second flank of a tooth each having asymmetrical dimensions that differ from one another. Furthermore, it is also provided that a first and a second foot region of a tooth have deviating, in particular asymmetrical oversizes.
  • a toothing element with a metallic sintered material can have a locally varied compression at least in the region of at least one flank of a tooth of the toothing element. This preferably enables elasticity of the powder metallurgical material, which is expedient for many applications, in conjunction with surface hardening. With gearwheels, for example, noise reduction during power transmission is particularly preferably made possible and, at the same time, good wear resistance is provided.
  • the toothing element can be a straight toothed gear.
  • the toothing element is a helically toothed gear wheel.
  • a bevel gear can also be provided.
  • opposing flanks of teeth of a toothing element have an asymmetrical compression.
  • there is asymmetrical compression in a foot area This compression is particularly adapted to the forces that occur during use.
  • the depth of the locally compacted edge layer is only so high that sufficient tooth elasticity or rigidity is still ensured.
  • the depth of the compacted edge layer in the foot region is particularly preferably less than on a tooth flank.
  • the toothing element is a cam.
  • the above statements are to be applied accordingly, for example flanks of the cam replacing the flanks of teeth.
  • an iron material is selected as the main component of the sintered material and at least one alloy component from the group consisting of carbon, molybdenum, nickel, copper, manganese, chromium and vanadium.
  • An iron alloy is, for example, Fe -1.0 Cr -0.3 V +0.2 based on a reference 15CrNiMo6.
  • Another iron alloy is, for example, Fe-1.5 Mo + 0.2C based on 20MnCr5.
  • Fe -3.5 Mo based on 16MnCr5 is provided as an iron-containing alloy.
  • the alloy C 0.2% Cr 0.5% Mn 0.5% Mo 0.5%, the rest including iron and impurities can be used.
  • other compositions can be provided.
  • a surface-compressed toothing made of sintered material can have at least 80% aluminum and at least copper and magnesium as further sintered materials.
  • a first embodiment provides that silicon is additionally used as the sintered material.
  • silicon can range from about 0.45% to about 0.8%, preferably between 0.6% and 0.75%. However, silicon can also be present in a higher range, for example between 13% and 17%, in particular between 14.5% and 15.5%. If the silicon content is higher, the copper content of the sintered material is reduced.
  • a first mixture can contain copper with a 4% to 5% content, silicon with 0.45% to about 0.8% content, magnesium with about 0.35% to 0.7% content and the rest at least mainly aluminum.
  • a pressing aid is preferably added. This can have a share between 0.8 and 1.8%.
  • a wax, especially amide wax can be used for this.
  • a second mixture can have, for example, copper with a 2.2% to 3% share, silicon with 13% to about 17% share, magnesium with about 0.4% to 0.9% share and the rest at least mainly aluminum.
  • a pressing aid can be used, as exemplified above.
  • At least one area of the toothing has a density of, for example, more than 2.5 g / cm 3 preferably up to the maximum density.
  • a workpiece produced in this way with a toothing preferably has a tensile strength of at least 240 N / mm 2 and a hardness of at least 90HB. If the silicon is higher, the density can in particular also be more than 2.6 g / cm 3 .
  • a second embodiment provides that, in addition, at least zinc is used as a sintered material in addition to copper and magnesium as additives and aluminum.
  • Copper preferably has a proportion in a range between 1.2% and 2.1%, in particular between 1.5% and 1.65%, magnesium between 1.9% and 3.1%, preferably between 2.45% and 2.65%, zinc between 4.7% and 6.1%, in particular between 2.3% and 5.55%.
  • the rest is at least mostly aluminum.
  • a pressing aid as described above can also be used here.
  • a workpiece made from this mixture with a toothing preferably has at least one area of the toothing after the surface compaction, in which a density of at least 2.58 g / cm 3 runs up to the maximum density.
  • a workpiece produced in this way with a toothing preferably has a tensile strength of at least 280 N / mm 2 and a hardness of at least 120HB.
  • a toothing element is sintered with a further functional component, in particular a shaft or a further gearwheel.
  • a further functional component in particular a shaft or a further gearwheel.
  • the gear element can be part of a pump.
  • it is an involute gear, which is brought into engagement with another involute gear.
  • the device comprises in particular at least one rolling tool, which can preferably act on the preform in an adapted engagement with the aid of the adapted tool control, preferably under an adapted pressure and / or controlled path.
  • the device comprises a rolling tool with a toothed surface which can be brought into engagement with the toothing of the toothing element and can be rolled thereon.
  • a device for producing an at least partially surface-hardened toothing element from a preform consisting at least in one surface area of a sintered material can comprise a tool which has a compensation of different dimensions on a first and a second flank of a tooth of the preform to be compressed by means of rolling motion.
  • the rolling tool can have a contour necessary for shaping, for example an involute toothing, only on one flank or on both flanks of a tooth.
  • a method for designing an oversize to achieve a surface compression of a sintered metal gear element during a rolling process is explained, the oversize being determined iteratively.
  • a geometry and in particular a torque and / or a pressure distribution are specified.
  • a design of a rolling tool is defined.
  • a preform with a locally defined oversize is determined.
  • a selection can be made, for example, using data libraries.
  • Such a data library contains, for example, experimental density profiles determined using various parameters.
  • the compression or rolling process can be simulated.
  • the kinematics of the rolling process is simulated in conjunction with a simulation of elastic and plastic properties of the preform and, if appropriate, of the rolling tool.
  • models of continuum mechanics are used in connection with a discrete solution using, for example, finite element or finite volume methods.
  • a geometry of a rolling tool is determined iteratively taking into account the oversize. For example, an oversize of an involute toothing of the rolling tool can be determined. A measurement for a toothing other than involute can be determined accordingly.
  • an allowance that is locally varied, at least pointwise, at least in a region of a flank of a tooth a preform of the toothing element is automatically generated on the basis of at least one design specification
  • a geometry of a rolling tool is automatically generated
  • a rolling process and a local course of compression of at least one edge layer of the toothing element generated in this way are simulated
  • an automatic evaluation of the generated course of the compression is compared with a specification and, if necessary, the process is repeated from the first step using at least one variation for optimization until an abort criterion is met.
  • the variation takes place, for example, with the help of an optimization process.
  • a termination criterion is, for example, a tolerance between the desired density profile and the density profile achieved in the simulation.
  • an abort criterion can also be a predefined number of iterations being exceeded.
  • the torque is to be understood here as the torque occurring in the intended use of a gear element.
  • a material stress is simulated at least in the area of the compression and is used in particular for the evaluation. This preferably avoids that a surface is sufficiently hardened, but is brittle due to tension and tends to crack.
  • data stored in a database library are used for variation.
  • methods for optimization and data analysis can be used, for example by means of neural networks.
  • Features stored in the database are also used, for example, for optimization using a genetic algorithm.
  • At least one of the steps can be replaced by a specification.
  • a rolling tool geometry is preferably predetermined. This takes into account, for example, the fact that a rolling tool is much more difficult to modify than, for example, a preform.
  • Another embodiment provides a reverse procedure. Starting from a final shape, a preform is preferred or the rolling tool for producing the final shape as well as the press tool for producing the preform.
  • a computer program product is proposed with program code means which are stored on a computer-readable medium in order to carry out at least one of the methods described above when the program is executed on a computer.
  • a computer-readable medium is, for example, a magnetic, a magneto-optical or an optical storage medium.
  • a memory chip is also used, for example.
  • a computer-readable medium can also be realized by means of a remote memory, for example by means of a computer network.
  • the computer program can, for example, be stored in a machine for surface compaction.
  • a calculation can also be carried out separately from the machine for surface compaction.
  • the machine has a control system, in particular a path-controlled and / or force-controlled control system, in which the coordinates and movement sequences can be entered in order to compress the preform.
  • a pressing tool mold is provided with which a preform made of sintered material can be pressed, which is subsequently surface-compacted onto a final mold.
  • This mold shape is calculated iteratively.
  • data of an end contour of the workpiece with its toothing are also used as the starting point.
  • a roller test stand can also be provided, which offers the possibility of being able to carry out test rolling for a wide variety of surface densifications.
  • data can also be determined in this way, which can be evaluated and included in the calculation methods.
  • suitable characteristic values can be formed from a large number of measurements. Starting values for the iterative calculation of preform, tool or pressing tool can be made using this.
  • the roller test stand can also have an automated measurement of surface-compacted workpieces that have teeth.
  • f H ⁇ means the deviation in terms of the toothing
  • F ⁇ the total deviation
  • f f ⁇ the profile shape deviation of the flanks.
  • the specified values correspond to the DIN classes with regard to the deviation.
  • an iteration takes into account parameters which relate to a material behavior when the tooth shape is surface-compacted.
  • an iteration to determine a preform is based on input data that are taken from a specification of the final shape. At least one rolling tool is preferably used, which has the same quality as the final shape created later.
  • the iterative determination and therefore extremely precise processing during surface compaction enables the quality of the tool to be transferred to the preform.
  • the extremely precise surface compaction enables the toothing to have this quality of the final shape after the surface compaction without a further material-removing finishing step.
  • a workpiece with the toothing is produced with a core density of at least 7.4 g / cm 3 with a surface density that is at a maximum in at least one area of a tooth flank, the maximum surface density in the area extending at least 0.02 ⁇ m in depth .
  • a method for producing a toothing from compressed sintered material wherein a pre-compressed tooth preform is compressed to its final shape at least in one area by means of iteratively determined data, and a roughness in the area is improved by at least 400% compared to the preform, with a surface hardness of at least 130 HB.
  • a core density of the final shape is set which has at least a density of 7.3 g / cm 3 , and a surface hardness is impressed which has a convex shape from the surface to a center of the final shape.
  • the teeth made of pre-compressed material have a roughness in a first surface-compressed area that is at least 400% smaller than a roughness in a second area that is less or not surface-compressed at all.
  • the roughness R z is, for example, less than 1 ⁇ m in the first region.
  • Another embodiment provides that there is a surface hardness of at least 700 HV [0.3] on the surface of the final shape, while at a depth of 0.4 mm from the surface there is at least a hardness of 500 HV [0.3] .
  • Another embodiment has a surface hardness of at least 700 HV [0.3] on the surface of a tooth flank and in a tooth base, a hardness of at least 500 HV [0.3] at a depth of 0.6 mm from the surface in the tooth base and a hardness of at least 500 HV [0.3] at a depth of 0.8 mm from the surface on the tooth flank.
  • the production of surface compaction makes it possible to set precise compaction as well as hardening according to the desired specifications.
  • a calculation method for the design of a preform of a toothing made of sintered material is now explained, wherein data are included in the calculation method, which are determined from a predetermined final shape of the toothing, depending on at least one condition of use of the final shape, one or more load parameters of the toothing are determined local allowance of the preform is calculated, which correlates with an expected compression of the preform on the surface, a load on the sintered material below the surface being included in the calculation.
  • the calculation is additionally based on penetration of the tool into the workpiece to be produced during the calculation, the behavior of the sintered material during penetration and after penetration being taken into account in particular.
  • the calculation method provides that elastic deformation of the sintered material to be compressed is taken into account.
  • the calculation method can also provide that elastic-plastic deformation of the sintered material to be compacted on the surface is taken into account.
  • a depth of a maximum load below the surface is preferably included in the calculation method when the workpiece is used as a force-transmitting gear.
  • the calculation method can further include shrinkage of the sintered material in the calculation during sintering.
  • Empirically determined data can also be included in the calculation.
  • a calculation method for designing a tool for the surface compression of a preform of a toothing made of, in particular, compacted sintered material for creating a predetermined tooth geometry can include that determined data from the predetermined tooth geometry to be produced for the calculation of machine tool kinematics, taking into account associated machine tools of a workpiece, from which the workpiece to be produced Tool is formed, and at least one tool former, whose coupled system coordinates and their movement to one another, are iteratively included. So now there is the possibility, instead of repeated Attempts to finally find measurement results and adaptations of the workpiece former to a final form, to carry this out using an iterative calculation. This is much more time-saving and enables a wide range of influencing parameters to be taken into account. In particular, a simulation of the design is also made possible, so that, for example, an operation of the tool to be manufactured on a designed preform can be checked in the simulation.
  • the calculation method can include contact conditions between the workpiece to be manufactured and the tool form maker between a tip and a foot of the toothing.
  • a maximum tension on the surface is also included in the calculation in the region of a base of the toothing.
  • a maximum tension below the surface is included in the calculation in the area of a flank of the toothing. This method is particularly suitable for sintered materials, but also for steel workpieces or workpieces made of other materials.
  • a compression molding tool with a press geometry for producing a preform of a toothing made of sintered material is described, the press geometry having a course adapted to a surface compression of the toothing with at least one elevation, which at least in the area of the toothing of the preform produces a depression which is made with sintered material during the Surface compaction is refillable.
  • the elevation on an end face of the preform preferably causes a depression in the region of a head of a tooth of the toothing.
  • the height of the elevation or depth of the depression as well as further dimensions thereof can be determined by iterative calculation.
  • Another embodiment provides, instead of a one-sided elevation, that a bilateral elevation is provided in order to bring about a depression on both end faces of the tooth.
  • the elevation is arranged in a region of the geometry which causes a depression on a tooth tip of the preform, the elevation being such that the shaped depression at least partially causes the tooth tip to grow due to the processing of the preform into the final shape by surface compaction at least diminished.
  • a preform with at least one recess on an end face of a toothing to compensate for a material throw-up when a running surface of the toothing is compacted can be calculated and in particular manufactured.
  • a preform with at least one recess on one can also be made in this way Calculate and, in particular, manufacture a tooth head of a toothing for at least reducing the tooth head from growing in height with a surface compaction of at least the flanks of the toothing.
  • the calculation method for determining a geometry of a preform or a compression molding tool preferably provides that the geometry is determined on the basis of data of a final shape of the preform and at least one depression or elevation is calculated, which at least partially compensates for a material shift during surface compaction.
  • a method for the surface compression of a toothing wherein a number of a repetitive compression movement of a molding tool for surface compression of a surface on the preform is calculated iteratively. Rollover is preferably calculated iteratively until a predetermined surface density is reached.
  • a feed of the molding tool is calculated iteratively.
  • the preform is rolled over less than 20 times in order to achieve the predetermined geometry of a final shape of the surface compaction. Rolling is preferably carried out less than 10 times.
  • the preform is rolled over less than 6 times until a predetermined geometry of a final shape of the surface compaction is achieved. It must be taken into account here that the surface compaction does not end when it is reached. Rather, the tool is then moved over the surface several times, in particular less than 25 times, preferably less than 15 times. This ensures an accuracy of the surface shape.
  • a method is proposed in which a reversing rolling is carried out on a toothing made of sintered material in order to compress the preform to the final shape of a surface compaction.
  • the preform is preferably relieved briefly by the molding tool. It has been found that by reversing, that is, by reversing the movement, a uniform compression can be created.
  • manufacturing problems were further minimized by reducing the pressure of the tool on the workpiece before the movement reversal started. The tool can remain in contact with the workpiece. But it can also detach itself from the surface for a short time.
  • a surface compaction of a workpiece with at least one toothing made of sintered material is proposed, with a first surface of the workpiece with another method is compacted than a second surface of the workpiece.
  • a first toothing of the workpiece preferably has a different compression than a second toothing of the workpiece.
  • An internal toothing of the workpiece undergoes a different surface compression than an external toothing of the workpiece.
  • an external toothing is surface-compressed by means of a rolling method, while a second surface is a bore which is surface-compressed by another method.
  • a hole in the workpiece is preferably given a hardened surface and is subsequently brought to a final shape. This allows the bore to be used for a shaft or an axis.
  • An improvement in the accuracy can be achieved by surface densification after hardening of the toothing.
  • a shaft with at least a first and with a second toothing can be designed such that the first toothing is rolled out of sintered material and is surface-compressed.
  • the shaft and the toothing are given below.
  • the further disclosure relating to the toothing, the materials, the manufacturing steps, etc. can be used in particular for further configurations.
  • the shaft has a second toothing, which is produced by a different method than the first toothing.
  • the second toothing forms a workpiece with the first toothing.
  • both teeth can be produced together in one press.
  • the first and the second toothing are preferably calculated iteratively and produced accordingly.
  • production can take place in succession, but according to another embodiment it can also take place simultaneously. In particular, this also applies to further processing steps such as surface compaction.
  • the second toothing has a hardened surface without surface compaction.
  • the density achieved by sintering or the inherent strength of the material used is sufficient. This applies, for example, to pump applications.
  • At least the first toothing has different flank slopes at the same height of the tooth at least on one tooth. This is advantageous in applications in which a main direction of rotation and in particular only one direction of rotation of the shaft is specified.
  • the different flank slopes can thus be designed to reduce wear and reduce noise.
  • the second toothing is forged. It can also be surface-compacted. This toothing can take up, for example, a greater power transmission than the first toothing.
  • the second toothing is preferably made of a different material than the first toothing.
  • the second toothing is made of steel.
  • the second toothing can also consist of a different sintered material than the first toothing.
  • the shaft can also be made of sintered material.
  • it can have the same material as the first toothing.
  • the shaft can also be formed at least together with the first toothing, i.e. be pressed from powder material, preferably in a common mold.
  • An exemplary method for producing the shaft described above can also provide that at least the first toothing is surface-compressed and a bore for receiving the shaft is surface-compressed, hardened and then honed before the shaft and the first toothing are connected to one another.
  • an iterative calculation of a preform of the first toothing is preferably carried out starting from a final shape of the shaft with the first toothing.
  • the preforms are arranged on shafts arranged in parallel and at the same time come into engagement with at least one tool for surface compaction.
  • At least two preforms are arranged on a common shaft and are brought together into engagement with at least one tool for surface compaction.
  • a movement of at least one shaft in which both preforms come into engagement with a tool for surface compaction.
  • at least three shafts for at least two preforms and at least one tool are arranged parallel to one another and form a triangle, wherein at least one of the shafts can be moved towards the other two shafts.
  • at least two preforms can be attached to a common shaft, the tool having a greater length than an added length of at least both preforms.
  • the preforms can preferably lie against one another with their end faces.
  • a distance is arranged between the preforms, the tool protruding along the shaft over both outer end faces of the preforms.
  • a component with a surface-compressed toothing made of sintered material can, viewed over a cross section, have a gradient with respect to the sintered materials used.
  • the component preferably has a gradient that has a step function.
  • the sintered materials are provided with a transition limit at least in this area. According to one embodiment, this transition boundary is present along the entire area between the first and second sintered material. Another embodiment provides that there is no fixed boundary in one area but a gradual transition. In particular, it can be provided that the component has different sintered materials that extend into one another without having a pronounced mixing zone with increasing or decreasing gradient.
  • the sintered material of the toothing can have a lower core density than the sintered material of an adjoining the toothing Area of the component.
  • a second variant of the component provides that the sintered material of the toothing has a higher core density than the sintered material of an area of the component adjoining the toothing.
  • Another variant has a component that has a first toothing with a first sintered material and a second toothing with a second sintered material.
  • a toothing preferably has different flank angles on a tooth at the same height.
  • a first sintered material can be arranged in an outer region of the component and form the toothing, and a second sintered material is arranged in an inner region of the component and forms a bore.
  • a method for producing a surface-compressed toothing on a component wherein a first sintered material is let into a mold before a second sintered material is added, then compression and sintering is carried out and only one of the two sintered materials is compressed by means of surface compression of the toothing. while the other sintered material does not change.
  • a further development provides that a second surface compaction is carried out, which only affects the sinter material that has not yet been surface-compacted. It is preferably provided that the first sintered material forms at least one surface of the tooth flanks and the second material forms a relining of the toothing.
  • Another proposed method for producing a surface-compressed toothing on a component provides for a first sintered material to be let into a mold before a second sintered material is added, then for pressing and sintering and for compressing the first and the second sintered material by means of surface compression of the toothing .
  • a movement sequence for surface compaction is iteratively determined taking into account a material behavior of at least one of the two sintered materials.
  • a development for both methods provides that a relative rotation acts between the mold, in particular a press mold, and a sintered material to be filled in, so that the sintered material collects in an outer region of the mold as a function of a speed of the relative rotation.
  • first and at least the second sintered material are added to the mold at least over a period of time.
  • the production method is also provided for grinding or honing the compressed tooth flanks and or tooth feet.
  • the forging preferably achieves a density of at least 7.6 g / cm 3 as the core density.
  • Surface compaction can therefore bring about full compaction and / or precision in the shape of the toothing.
  • an allowance for this step is in a range of 4 ⁇ m to 8 ⁇ m material above the final dimension.
  • honing it is preferably 30 ⁇ m to 50 ⁇ m and for grinding 50 ⁇ m to 0.3 mm, preferably 0.1 mm to 0.2 mm, according to the allowance Surface compaction provided.
  • the iterative calculation makes it possible to determine the areas and dimensions in advance and to be able to implement them later in the process.
  • a surface compaction is preferably also provided, followed by hardening and then preferably honing.
  • the bore can also have an allowance between 30 ⁇ m and 50 ⁇ m after the surface compaction.
  • oils can also be used for lubrication. This is preferred for hot rolling, for example at temperatures of over 220 ° C. In addition, it is proposed to carry out the hot rolling at a temperature between 500 ° C. and 600 ° C., oil cooling preferably being used to lubricate on the one hand and to cool the tool on the other hand.
  • Fig. 1 shows an exemplary rolling arrangement in a schematic view.
  • a first rolling tool 101 with a first toothing 102 is rotatably mounted about a first axis 103 in a direction of rotation 104.
  • the first toothing 102 is in engagement with a second toothing 105 of a preform 106.
  • the preform 106 is rotatably mounted about a second axis 107.
  • a second direction of rotation 108 results accordingly.
  • the second toothing 105 is in engagement with a third toothing 109 of a second rolling tool 110.
  • This second rolling tool 110 is rotatably mounted about a third axis 111 in a third direction of rotation 112.
  • the first axis 103 or the second axis 107 can be fixed axes, while the other two axes can execute an infeed movement.
  • the third axis 111 can be displaced in a displacement direction 113 along a connecting line 114 of the first 103, the second 107 and the third axis 111.
  • a dimension rolling process can be carried out.
  • tooth flanks in particular are only slightly compressed and in particular the tooth bases are not compressed. This results in surface compaction in a desired area.
  • the tooth base can also be surface-compacted only or additionally. For example, a progressive shift takes place in the direction of the shift direction 113 during a rolling process.
  • a region of the tooth feet of the preform 106 is also compacted by means of the first and second rolling tools 101, 110.
  • an adjusting device is preferably provided with a gear. Very high pressures can also be applied in particular.
  • Fig. 2 shows a first tooth 201 of an associated toothing element, not shown.
  • This gear element is a gear.
  • a geometry of the toothing element or of the first tooth 201 is characterized by a first root circle 202, a first root useful circle 203, a first pitch circle 204 and a first tip circle 205.
  • the first tooth 201 On a first flank 206, the first tooth 201 has a first oversize curve 207 before a rolling process.
  • a first gauge block course 208 After an ended Rolling results in a first gauge block course 208, correspondingly resulting in a first compacted edge layer 209.
  • This is shown schematically by a first compression boundary line 210. This line delimits the area of the first tooth 201 within which the full density is reached.
  • the full density is preferably based on a density of a comparable powder-forged tooth.
  • Fig. 3 shows a second tooth 301 of a toothing element, not shown.
  • This gear element is also a gear.
  • the second tooth 301 and the gearwheel are characterized by a second tip circle 302, a second pitch circle 303, a second root useful circle 304 and a second root circle 305.
  • a second oversize profile 308 and a third oversize profile 309 are provided to achieve an identical compression profile on a second flank 306 and a third flank 307.
  • a second gauge block curve 310 results on the second flank 306 and a third gauge block curve 311 on the third flank 307.
  • a second compression limit line 312 and a third compression limit line 313 result.
  • the second oversize profile 308 and the third oversize profile 309 are configured differently.
  • the different effects of forces on the tooth flanks 306, 307 during a rolling process are illustrated by the sliding speed directions shown.
  • a first 314 and a second sliding speed direction 315 result on the second flank 306. Starting from the second pitch circle 303, these are directed in the direction of the second tip circle 302 and in the direction of the second root circle 305.
  • On the third flank 307 results in a third sliding speed direction 316 and a fourth sliding speed direction 317, which are directed towards each other.
  • Fig. 4 shows a third tooth 401 of a toothing element, not shown.
  • This gear element is also a gear.
  • Gearwheel and third tooth 401 are in turn characterized by a third tip circle 402, a tip usage circle 403, a third pitch circle 404, a third root usage circle 405 and a third root circle 406.
  • the third tooth 401 shown is a toothing with a head relief, preferably in the form of a rounded head. However, other geometries are also possible in this area.
  • a tooth profile is withdrawn in a tooth tip region 401.1 between the third tip circle 402 and the tip usable circle 403. As a result, the tooth does not engage with an involute counter-toothing in this area.
  • a fourth measurement curve 407 results after a rolling process in a fourth compression limit line 408. Furthermore, a fourth gauge block curve 410 is formed on the fourth flank 409 achieved.
  • Fig. 5 shows an oversize curve between two adjacent teeth of a toothing element, not shown.
  • This gear element is in turn a gear wheel.
  • Gear and teeth are characterized by a fourth root circle 502, a fourth useful circle 503 of the preform, a fifth useful circle 504 of the preform after a grinding process, a fourth circle 505 after a milling process and a fifth circle 506 after a finishing process.
  • a fifth gauge block curve 507 results.
  • a lateral dimension in millimeters is plotted on the abscissa axis. On the ordinate axis, the corresponding lateral dimension, which is oriented perpendicular thereto, is also plotted in millimeters.
  • the gearing runs completely in the drawing plane.
  • Fig. 6 shows a compilation of further measurement courses.
  • the nominal floor length is shown along a flank line of a gear element.
  • This curve line relates to a course from a tooth head of a first tooth to a tooth head of an adjacent tooth.
  • the absolute arc length of the corresponding flank line is shown in millimeters on the upper axis of the abscissa.
  • the left ordinate axis indicates an oversize in millimeters.
  • the right ordinate axis describes the corresponding radius of the associated toothing.
  • a sixth oversize curve 601, a seventh oversize curve 602 and an eighth oversize curve 603 are shown. Furthermore, an associated radius 604 of the corresponding toothing is shown.
  • the sixth oversize curve 601 and the eighth oversize curve 603 are designed symmetrically to a tooth base symmetry line 605.
  • the seventh measurement curve 607 is designed asymmetrically.
  • the measurements In the vicinity of the tooth symmetry base line 605, that is to say in the area of the tooth base, the measurements each have a local minimum. This promotes a reduction in the risk of stress cracking.
  • Fig. 7 shows another measurement course.
  • a ninth measurement curve is shown, which runs asymmetrically from a left tooth head 702 to a right tooth head 703.
  • An oversize in the area of a tooth base 704 is also shown here less than in the area of the fifth 705 and the sixth flank 706. This serves in particular to avoid stress cracks.
  • Fig. 8 shows a first process scheme.
  • a geometry of a rolling tool is generated with a first geometry generation module 802.
  • a geometry of a preform is generated in a second geometry generation module 803 both on the basis of the target 801 and on the basis of the geometry of the rolling tool.
  • a rolling process is simulated in a first simulation module 804. Both a kinematics of the rolling process and the compression process that is caused during the rolling process are simulated.
  • a redistribution of material such as that in Fig. 3 is outlined.
  • the plastic deformation is simulated here, for example, using a finite element method.
  • a second simulation module 805 can optionally be taken into account for simulating a bracing.
  • This module includes both the target 801 and the geometry of the preform.
  • the second simulation module 805 also enables the determined geometry of the preform to be corrected.
  • the first geometry generation module 802, the second geometry generation module 803, the first simulation module 804 and optionally the second simulation module 805 can be repeatedly executed in an optimization loop.
  • Fig. 9 shows a second process scheme.
  • a ninth measurement curve 902 of a tooth profile 903 is generated.
  • a second tooth profile 905 of a third rolling tool 906 is then generated in a second step 904.
  • a rolling process is simulated in a third step 907.
  • the rolling process of the first tooth profile 903 on the second tooth profile of the rolling tool 905 and the resulting compression are simulated.
  • the first, second and third steps 901, 904, 907 are then optionally repeated in a variation 908.
  • Fig. 10 shows an oversize curve of a gear element of a rolling tool.
  • a tenth dimension curve 1001 of a fifth tooth 1002 of a rolling tool, not shown, is shown.
  • a different allowance is provided on a seventh flank 1003 and an eighth flank 1004 of the fifth tooth 1002.
  • On the seventh Flank 1003 a material addition is provided, which is indicated by a first arrow 1005.
  • a tooth relief is provided on the eighth flank 1004, which is indicated by the second arrow 1006.
  • the measurement is based on a regular profile of an involute toothing.
  • the asymmetrical configurations of the two tooth flanks 1003, 1004 take into account in particular an asymmetrical material load on a toothing element to be compressed therewith.
  • a symmetrical profile of both flanks of a tooth can be achieved by means of this rolling tool, for which compensations in the range of preferably less than 0.1 ⁇ m are carried out.
  • Fig. 11 shows a schematic view of a calculated depression on an end face of a toothing.
  • the depression serves to at least minimize, if not even compensate, for a growth of the displacement of sintered material achieved by the surface compaction and the associated growth of the tooth in height and / or width.
  • the shape of the recess depends on the oversize and the dimensions of the tooth. The shape can be iteratively optimized using the calculation method. A simulation enables the actual behavior of the preform to be estimated later.
  • Fig. 12 shows a schematic view of calculated extreme cases of tools for surface compaction, which can be calculated.
  • the starting point of the calculation is the left end geometry of the toothing.
  • the tool shapes shown in the middle and right of it can be determined iteratively by taking into account rolling conditions, measurement parameters and other influencing factors.
  • Fig. 13 is a schematic view of a procedure in the iterative calculation and links in a simulation.
  • the machine kinematics can be modeled based on the specified end data of the workpiece and its gearing. Here, for example, the mutually assigned machine axes are assumed.
  • the kinematics and functional links can then be used to optimize the tool to be designed using the existing degrees of freedom. This is again on Fig. 12 referred.
  • the examples shown there have corresponding disadvantages, for example, the foot region is too weak in the middle display or the head design is too pointed in the right display.
  • An iteration towards one for the respective requirement profile can then take place via additional influencing parameters such as, for example, strength considerations and / or stress profiles in the material suitable contour of the tool.
  • the end geometry determined with the calculated oversizes is taken as the starting point.
  • Fig. 14 shows a view of density profiles as a function of different initial densities of the preforms used. If the density of the preform is changed in its core as well as in the course towards the outside, there are influences regarding the course of the surface compression. This goes from the right picture of the Fig. 14 forth. By changing the respective preform, the course of density after surface compaction can also be strongly influenced. Therefore, the initial core density as well as the shape of the preform are important parameters in the iteration and calculation.
  • Fig. 15 gives an example of an overview of the errors that occur during different surface compaction steps and that characterize the material behavior.
  • the error is specified in error classes according to DIN 3972 or DIN 3970.
  • An important point in determining a suitable surface compaction by rolling is the profile change of the rolling tool.
  • This is in Fig. 15 shown on a preform with a core density of 7.3 g / cm 3 , which was in engagement with an unmodified set of rolling tools and was surface compacted.
  • the geometry of the gear wheel changes depending on a feed movement of the rolling tool. The goal is to achieve the desired final contour as specified. From the illustrations of the Fig.
  • the profile angle error is shown as an example on the left, the complete profile shape error in the middle and the shape error on the right. These were measured on the gear manufactured in each case.
  • a tooth thickness reduction of 0.27 mm leads to a profile angle deviation corresponding to class 7 according to DIN.
  • a feed of 0.4 mm is necessary.
  • the finished contour comes to lie in the other values outside the necessary quality classes. It is therefore necessary to change the geometry of the tool. Taking into account the found values as input values, a new tool can then be determined, the tests carried out again and in this way iteratively an optimized geometry for determine the tool.
  • the calculation enables a final contour for the tool to be determined with, for example, two or only one iteration.
  • Fig. 16 shows a hardness curve in HV on a flank of a toothing plotted over the distance from the surface on the x-axis in [mm].
  • the profile profile of the hardness can be influenced by suitable dimensioning as well as feed movement.
  • the course can be at least partially convex or concave.
  • the preform labeled AVA7-1 had a larger oversize than the preform labeled AVA4-2. Both have an opposite course of hardness: while in the first part until 550 HVAVA7-1 has a rather convex shape, AVA4-2 has a more concave course. After falling below 550HV, this changes.
  • Fig. 17 a hardness curve in HV in a foot area of a toothing with different surface compaction steps. Due to the smaller oversize there compared to the flank oversize and due to the geometry, the hardness profile is different. The hardness drops more steeply at the beginning, but then almost changes into a straight course with only a slight incline.
  • Fig. 18 shows a schematic view of different calculated oversize curves for different densities based on a final tooth thickness.
  • the diameter is plotted on the y-axis.
  • the oversize is indicated on the x-axis.
  • D_a or d_a specifies the tip usable circle diameter or the tip circle diameter, 0 is a specification of an oversize, for example by a value on the pitch circle, d_b is the base circle diameter.
  • A indicates the range of preferred values for the pitch circle range.
  • B represents a critical area, since material failure during rolling can already occur there.
  • Fig. 19 shows a schematic representation of parameters that can be included in the iterative calculation. In particular, these can be places of maximum stress. As shown in the photo on the left, pitting damage can occur on the flank. A reference stress curve is therefore preferably used, in which the following applies: a maximum stress occurs below the surface, in particular in the region of a negative slip, and therefore preferably below the specified pitch circle diameter d_w1.
  • the right photo shows a tooth break due to excessive bending load. From that follows for the calculation model that a location of the maximum tooth foot stress is determined and taken into account. This can be determined, for example, using the 30 ° tangent according to DIN or using the Lewis parabola according to AGMA. For the comparison voltage, it is preferably assumed that a maximum voltage occurs on the surface.
  • Fig. 20 shows a schematic view of a further possibility, for example, how at least two preforms can be compressed simultaneously.
  • the preforms can also be moved in the direction of the tool.
  • two or more preforms are arranged on a preform axis.
  • the invention can be used, for example, in camshaft gears, in planetary gears, in sun gears, in drive gears, in differential gears, in gear gears, in clutch gears, in pump gears, in straight-toothed gears, in helical gears, in electric motors, in internal combustion engines, in actuators, in variable speed drives or internal gears, for external or internal helical gear units with straight or helical gears, for bevel gear units with straight, helical or curved teeth, for helical gear units or worm gear units as well as for high-helix shaft and high-helix hub connections.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Gears, Cams (AREA)

Claims (12)

  1. Procédé de fabrication d'un endentement en matière frittée, dans lequel une ébauche (106) est associée à au moins une surépaisseur négative déterminée au moyen d'un calcul itératif, qui est remplie au moins partiellement par le déplacement de la matière frittée lors d'un compactage de surface de l'endentement (105) ; dans lequel la surépaisseur négative est disposée au moins sur un flanc d'une dent de l'endentement (105).
  2. Procédé selon la revendication 1, caractérisé en ce qu'une matière de surépaisseur adjacente à la surépaisseur négative est déplacée dans la surépaisseur négative.
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que l'ébauche (106) est compactée en surface en la forme finale souhaitée, dans lequel un durcissement et/ou une finition de surface est facultativement effectué.
  4. Procédé selon l'une des revendications précédentes, dans lequel la surépaisseur négative s'étend de manière asymétrique le long du flanc.
  5. Procédé selon l'une des revendications précédentes, dans lequel une surépaisseur négative est prévue sur chaque flanc d'une dent.
  6. Procédé selon l'une des revendications précédentes, dans lequel une dent de même hauteur présente une première surépaisseur négative sur un premier flanc et une deuxième surépaisseur négative sur un deuxième flanc, dans lequel les premier et deuxième flancs s'étendent de façon asymétrique l'un par rapport à l'autre.
  7. Procédé selon l'une des revendications précédentes, dans lequel la surépaisseur négative est disposée sur un flanc de la dent entre une zone de tête de la dent et une surépaisseur.
  8. Procédé selon l'une des revendications précédentes, dans lequel la surépaisseur négative est en outre disposée dans une zone d'angle de la base de la dent.
  9. Procédé selon l'une des revendications précédentes, dans lequel l'endentement présente, sur au moins une dent, des inclinaisons de flanc respectives différentes à la même hauteur de la dent.
  10. Procédé selon l'une des revendications précédentes, dans lequel l'endentement (105) est un endentement interne.
  11. Procédé selon l'une des revendications précédentes, dans lequel ladite ébauche (106) se transforme en une roue dentée compactée en surface.
  12. Produit de programme d'ordinateur comprenant des moyens à code de programme stockés sur un support lisible par ordinateur pour mettre en oeuvre un procédé selon au moins l'une des revendications 1 à 11 lorsque le programme est exécuté sur un ordinateur.
EP06754213.4A 2005-06-10 2006-06-08 Procédé de fabriquer un endentement de matérieau fritté Active EP1890831B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102005027142A DE102005027142A1 (de) 2005-06-10 2005-06-10 Vorformgeometrie einer Verzahnung
PCT/EP2006/005467 WO2006131348A2 (fr) 2005-06-10 2006-06-08 Geometrie d'ebauche pour un endentement

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EP1890831B1 true EP1890831B1 (fr) 2020-07-29

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EP (1) EP1890831B1 (fr)
CN (1) CN101193719B (fr)
CA (1) CA2611597A1 (fr)
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DE102010039491A1 (de) 2010-08-18 2012-02-23 Deckel Maho Pfronten Gmbh Verfahren und Vorrichtung zum Erzeugen von Steuerdaten zur Ausbildung einer Zahnflanke durch fräsende Bearbeitung eines Werkstücks an einer Werkzeugmaschine
AT509456B1 (de) * 2010-08-31 2011-09-15 Miba Sinter Austria Gmbh Gesintertes zahnrad
AT510985B1 (de) 2011-07-22 2012-08-15 Miba Sinter Austria Gmbh Baugruppe mit zwei stoffschlüssig miteinander verbundenen bauteilen
ITTV20120122A1 (it) * 2012-06-25 2013-12-26 Breton Spa Metodo, sistema e apparato per la lavorazione di ruote dentate.
CN104174931B (zh) * 2014-05-04 2017-02-22 湖北大学 一种间歇式自适应磨前磨后测量和免测量的锯齿磨削方法
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DE102015112322A1 (de) * 2015-07-28 2017-02-02 Hoerbiger Antriebstechnik Holding Gmbh Verfahren zum Herstellen eines Synchronrings sowie Synchronring
EP3398710A4 (fr) * 2015-12-31 2019-07-24 Kwang Hui Lee Procédé de fabrication d'engrenage et engrenage fabriqué par ledit procédé
AT15793U1 (de) 2017-05-16 2018-07-15 Miba Sinter Austria Gmbh Verfahren zum Verdichten der Innenverzahnung eines Zahnrades
DE102017214297A1 (de) 2017-08-16 2019-02-21 Thyssenkrupp Ag Schiebeelement mit partiell gehärteter Rasterhebung
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Also Published As

Publication number Publication date
EP1890831A2 (fr) 2008-02-27
US20080134507A1 (en) 2008-06-12
CN101193719A (zh) 2008-06-04
US8307551B2 (en) 2012-11-13
CA2611597A1 (fr) 2006-12-14
CN101193719B (zh) 2016-02-03
WO2006131348A3 (fr) 2007-03-15
WO2006131348A2 (fr) 2006-12-14
DE102005027142A1 (de) 2006-12-14

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