WO2022218455A1 - Composant et procédé de production d'un composant au moyen d'une technologie de formage - Google Patents

Composant et procédé de production d'un composant au moyen d'une technologie de formage Download PDF

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Publication number
WO2022218455A1
WO2022218455A1 PCT/DE2022/000028 DE2022000028W WO2022218455A1 WO 2022218455 A1 WO2022218455 A1 WO 2022218455A1 DE 2022000028 W DE2022000028 W DE 2022000028W WO 2022218455 A1 WO2022218455 A1 WO 2022218455A1
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WO
WIPO (PCT)
Prior art keywords
blank
component
produced
forming
percent
Prior art date
Application number
PCT/DE2022/000028
Other languages
German (de)
English (en)
Inventor
Daniel Schoener
Holger NAECKEL
Original Assignee
Neumayer Tekfor Engineering Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Neumayer Tekfor Engineering Gmbh filed Critical Neumayer Tekfor Engineering Gmbh
Publication of WO2022218455A1 publication Critical patent/WO2022218455A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/008—Incremental forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/28—Making machine elements wheels; discs
    • B21K1/30—Making machine elements wheels; discs with gear-teeth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06—Surface hardening
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06—Surface hardening
    • C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
    • C21D1/10—Surface hardening by direct application of electrical or wave energy; by particle radiation by electric induction
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/13—Modifying the physical properties of iron or steel by deformation by hot working
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/32—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for gear wheels, worm wheels, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/10—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for compacting surfaces, e.g. shot-peening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C3/00—Abrasive blasting machines or devices; Plants
    • B24C3/32—Abrasive blasting machines or devices; Plants designed for abrasive blasting of particular work, e.g. the internal surfaces of cylinder blocks
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2261/00—Machining or cutting being involved
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
    • F16H55/02—Toothed members; Worms
    • F16H55/06—Use of materials; Use of treatments of toothed members or worms to affect their intrinsic material properties
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
    • F16H55/02—Toothed members; Worms
    • F16H55/17—Toothed wheels
    • F16H55/18—Special devices for taking up backlash
    • F16H55/20—Special devices for taking up backlash for bevel gears

Definitions

  • the present invention relates to a component. Furthermore, the invention relates to a method for producing a component by forming.
  • a production sequence known in the state of the art consists of the following steps: hot forming, blasting, soft annealing, blasting, coating, warm forming, machining, case hardening, blasting and hard machining.
  • An alternative process provides: hot forming, soft annealing, blasting, coating, cold forming, machining, case hardening, blasting and hard machining.
  • the object on which the invention is based is to improve the metal forming production of components with regard to the energy balance.
  • the invention solves the problem with a component.
  • the object is achieved by a method for producing a component by forming.
  • the object is achieved according to the invention by a component which has been produced from a blank by forming, the blank having a carbon content greater than 0.2 percent by weight.
  • the blank preferably has a carbon content of between 0.4 percent by weight and 0.7 percent by weight.
  • the blank from which the component has been produced by means of a forming process is therefore not made from a customary or common case-hardening steel because it has a higher carbon content.
  • the component has been produced from the blank in at least the following steps: in a first step, the blank has been heated to a temperature—preferably between 800° C. and 1,050° C.—above a temperature at which austenitization of the blank begins that in a second step the blank heated in the first step has been sheared off and completely formed, and that in a third step the formed blank has been subjected to controlled cooling.
  • a temperature preferably between 800° C. and 1,050° C.
  • the second step comprises warm forging. Due to the semi-hot forming (the temperature is below 1,050 °C) at the beginning of the manufacturing process instead of the hot forming customary in the prior art, the forming steps required in the prior art and, for example - in the case of a blank made of a high-carbon steel - case hardening can also be carried out omitted. In the prior art, for example, it would be necessary to carry out case hardening in the case of a blank made of case-hardening steel during warm forming. This step is not necessary with a blank made of a high-carbon steel.
  • the advantage is a shortened production time and a reduced energy requirement.
  • the invention is thus advantageously characterized by resource efficiency and by the reduction in energy requirements.
  • the semi-hot forming takes place at a temperature above a temperature at which austenitization of the material of the blank begins. This lower temperature value for austenitization depends on the material and is between around 850 °C and 1,050 °C for most materials.
  • Austenitization means that as a result of a heat treatment of iron, ferrite is converted into austenite, i.e. the conversion of a body-centered cubic crystal structure into a mixed crystal consisting of iron and carbon, takes place.
  • the temperature range in which austenitization takes place extends up to the melting point of the respective material. However, the warm working temperature is below the melting point. In one embodiment, the temperature of the semi-hot forming is at most 1,050°C.
  • the component is a differential bevel gear.
  • the peculiarity of this design is that a complex structure like that of a differential bevel gear is created from a material with a high carbon content.
  • One configuration of the component is that the blank is in the form of a rod.
  • the second step is a Netshape forming process.
  • the component is a differential bevel gear
  • the forming above the temperature of the onset of austenitization in combination with the forging of the finished functional geometry in the second step, preferably using netshape forming represents a special feature compared to the prior art
  • the functional geometry is given by the toothing.
  • One configuration of the component provides that the component has such a predetermined core structure in a core area as was produced by cooling in the third step. Through the targeted cooling in the third step, a desired core structure is created in the component. In the third step, the carbon distribution essentially does not change and is essentially constant over the cross section of the component, in particular when using a high-carbon steel for the blank.
  • One configuration of the component is that in the third step a specified core structure has been produced in a core area, and that the specified core structure is related to application characteristics of the component. The application characteristics relate z. B. on the hardness, toughness or fatigue strength that the component has to have for the application.
  • One configuration of the component provides that, before the first step, no heating of the blank that affects the material properties has been carried out.
  • the blank itself may have been heated during its production. However, this would not be part of the manufacturing process of the component according to the invention.
  • the blank is therefore still only characterized by its carbon content of more than 0.2 percent by weight. According to the invention, however, no preheating is required before the first step.
  • One configuration of the component consists in that, in the second step, a running gear has been produced by forming.
  • the running gearing is a functional geometry of the component, which is produced in the second step by forming.
  • One configuration of the component provides that a functional geometry generated in the second step has not undergone any further shape-changing processing.
  • the second step gave the component its final functional geometry. Further forming or machining operations to create the desired functional geometry are no longer required.
  • the functional geometry is the toothing, which is completely created in the second step. Further processing steps, which also produce special geometries, can follow the second step in the different configurations. However, this then refers to other sections of the component and not to the functional geometry.
  • the toothing is not formed or subjected to machining.
  • One configuration of the component is that in the second step the blank has heat at its disposal that was introduced into the blank in the first step. This saves the energy to be expended.
  • the semi-hot forming of the second step is therefore part of an interlinked heat treatment. By combining forming and heat treatment, the result is a very efficient and resource-saving overall process.
  • One configuration of the component provides that a depression has been produced in the blank and that after the third step the depression has been machined.
  • the indentation was produced in the second step and/or by forming.
  • the recess is a through hole. In an alternative embodiment, the recess has a base.
  • One configuration of the component is that after the third step, a side of the blank facing away from the functional geometry produced in the second step is machined.
  • One configuration of the component provides that after the third step, a functional geometry of the blank produced in the second step is at least partially subjected to induction hardening. Induction hardening brings the surface to a desired value and hardness profile in terms of hardness.
  • One configuration of the component is that the component has martensite formation generated by the induction hardening and an initial hardness according to the carbon content on the surface (this is preferably the outside), and that the martensite formation is related to application characteristics - in particular hardness and / or toughness and /or fatigue strength - of the component.
  • One embodiment of the component provides that only teeth of the functional geometry produced in the second step have been subjected to induction hardening. In this configuration, the functional geometry has teeth. In this configuration, the teeth are therefore a special form of the functional surfaces of the functional geometry. Therefore, in a general configuration, only the functional surfaces of the functional geometry produced in the second step have been subjected to induction hardening. The functional surfaces are primarily the sections or areas of the functional geometry that are exposed to the greatest mechanical stress when the component is used.
  • all sections of the component that are subject to mechanical stress, e.g. B. through contact with other components are subject to induction hardening.
  • One configuration of the component is that teeth and intermediate sections between the teeth of the functional geometry produced in the second step have been subjected to induction hardening.
  • One configuration of the component provides that functional surfaces and intermediate sections between the teeth of the functional geometry produced in the second step have been subjected to induction hardening.
  • One embodiment of the component provides that in the second step a functional geometry with teeth has been produced and that the component has a greater penetration depth of hardened material in a head area of the teeth than in the associated foot areas.
  • the flanks of the teeth between the head area and the associated foot areas can have a variable depth of penetration.
  • One configuration of the component consists in the component being at least partially subjected to a surface treatment—in particular blasted—after the third step.
  • One configuration of the component provides that the component has a substantially constant carbon content and that the hardness of the component is higher towards the outside than in a core area.
  • the component thus has a hardness profile that decreases from the outside to the inside and that is comparable to the profile that is produced from blanks made of case-hardening steel according to the prior art.
  • the carbon content is - in contrast to the components according to the prior art
  • One configuration of the component is that the component has been produced without a carburizing process.
  • the invention solves the problem with a method for producing a component—in particular a differential bevel gear—from a blank by metal forming, the blank having a carbon content greater than 0.2 percent by weight
  • the method having at least the following steps: that in a first step the blank is heated to a temperature - preferably between 800 °C and 1,050 °C - above a temperature of the blank in which austenitization takes place, that in a second step the blank heated in the first step is sheared off and completely formed, and that in a third step the formed blank is subjected to controlled cooling.
  • One embodiment of the method is that a netshape forming method is carried out in the second step.
  • a predetermined core structure is produced in a core area in the third step.
  • essentially no change in the carbon distribution is made in the third step. The carbon distribution is essentially constant over the entire cross section of the component, in particular when using a blank made of steel with a higher carbon content.
  • One embodiment of the method consists in that in the second step a running gear is produced by forming.
  • One embodiment of the method provides that heat is introduced into the blank in the first step and that the heat introduced is used in the second step.
  • One embodiment of the method consists in that—preferably in the second step and/or preferably by forming—a depression—in particular a continuous bore—is produced in the blank, and that after the third step the depression is machined.
  • One embodiment of the method provides that after the third step, a side of the blank facing away from the functional geometry produced in the second step is machined.
  • One embodiment of the method consists in that, after the third step, a functional geometry of the blank produced in the second step is at least partially subjected to induction hardening.
  • One embodiment of the method provides that only teeth of the functional geometry produced in the second step are subjected to induction hardening. In an alternative embodiment, teeth and intermediate sections between the teeth of the functional geometry produced in the second step are subjected to induction hardening.
  • One embodiment of the method consists in the component being at least partially subjected to a surface treatment—particularly blasted—after the third step.
  • FIG. 1 shows a section through a blank and a spatial representation of a component produced according to the invention
  • FIG. 5 shows a schematic sequence of the production steps of the method according to the invention.
  • FIG. 1a shows a section through a blank 1, which is circular-cylindrical and is rod material.
  • FIG. 1 b shows a component 2 in the form of a bevel gear produced from such a blank 1 .
  • the outside 25 or surface of the functional geometry 20 that can be seen here has only undergone a hardening treatment after the forming.
  • FIG. 2 shows a section through a blank after forming and before a machining step.
  • the continuous cutout 22 is circular-cylindrical in this example.
  • the recess can be crowned or have a spline.
  • the dashed lines indicate that the recess 22 and the side 23 facing away from the functional geometry are machined. At these points, which are not relevant to the actual function of the component, the geometry is not only generated by forming, but is also created by machining or brought into the desired final state. 3 shows an enlarged section through a tooth 200 of the functional geometry 20, ie the running geometry.
  • the dashed line indicates the course of the hardness from the outside to the core area (cf. FIG. 2). It can be seen that the penetration depth in the head area 201 extends much deeper than in the foot area 202 . Thus, the tip or head of the tooth 200 has been hardened over a larger area than the root area 202 and thus also the valley-shaped areas between the teeth 200.
  • FIG 4 shows the course of the carbon content c in a case-hardened steel (solid line) and a steel used according to the invention with a higher carbon content (dashed line).
  • the values are plotted against the edge distance t. As the enlargement of a tooth makes clear, the edge distance t is measured from the surface of the component in the direction of the core area (cf. Fig. 2).
  • the carbon content has the same value over the entire depth - i.e. over every edge distance t - in steel with a higher carbon content. This is due to the fact that the blank already has a high carbon content and that it is not necessary to increase the carbon content through a machining process. In the prior art, this always leads to the carbon content being higher at the edge than in the core area, since the carbon has been introduced into the component from the surface. This is shown by the solid line for case hardening steel. In the case of case hardening steel, the hardness also decreases from the outside inwards, ie with a larger edge distance t.
  • FIG. 5 shows an embodiment of a flow chart of the forming method according to the invention.
  • the blank is subjected to heating.
  • the blank has a carbon content greater than 0.2 percent by weight.
  • the functional geometry is finished by semi-hot forming. This is preferably done at a temperature above the temperature at which austenitization of the material of the blank takes place, but below 1050°C. The function geometry then does not require any processing that affects the geometry.
  • the formed blank is subjected to controlled cooling, which in one embodiment is followed by machining. In a further treatment, at least part of the functional geometry is induction hardened.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Heat Treatment Of Articles (AREA)

Abstract

L'invention concerne un composant (2) qui est produit à partir d'une ébauche (1) au moyen d'une technologie de formage, l'ébauche (1) présentant une teneur en carbone supérieure à 0,2 % en poids. Le composant (2) est produit à partir de l'ébauche (1) à l'aide des étapes suivantes. Dans une première étape (101), l'ébauche (1) est chauffée à une température supérieure à une température de l'ébauche (1) à laquelle l'ébauche (1) commence à s'austénitiser. Dans une deuxième étape (102), l'ébauche (1) chauffée dans la première étape est cisaillée et subit un formage final. Dans une troisième étape (103), l'ébauche formée (1) est soumise à une procédure de refroidissement contrôlée. L'invention concerne également un procédé de production d'un composant (2) à partir d'une ébauche (1) au moyen d'une technologie de formage.
PCT/DE2022/000028 2021-04-12 2022-03-18 Composant et procédé de production d'un composant au moyen d'une technologie de formage WO2022218455A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021001875.3A DE102021001875A1 (de) 2021-04-12 2021-04-12 Bauteil sowie Verfahren zum umformtechnischen Erzeugen eines Bauteils
DE102021001875.3 2021-04-12

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Publication Number Publication Date
WO2022218455A1 true WO2022218455A1 (fr) 2022-10-20

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5718774A (en) * 1995-07-27 1998-02-17 Nissan Motor Co., Ltd. Method of producing bevel gear
DE19734563C1 (de) 1997-08-04 1998-12-03 Mannesmann Ag Verfahren zur Herstellung von Wälzlagerringen aus Stahl
DE10065737A1 (de) 1999-12-31 2001-07-12 Dana Corp Induktionsgehärtetes geschmiedetes (Zahrad-) Getriebe und Verfahren zum Vorbereiten desselben
DE102012017525A1 (de) 2011-09-10 2013-03-14 Volkswagen Aktiengesellschaft Verfahren zur umformenden Herstellung eines Zahnrads mit Außenverzahnung, sowie nach diesem Verfahren herstellbares Zahnrad mit Außenverzahnung
JP5405325B2 (ja) * 2010-01-04 2014-02-05 新日鐵住金株式会社 差動歯車およびその製造方法
US20160361784A1 (en) 2015-06-15 2016-12-15 American Axle & Manufacturing, Inc. Net forged spiral bevel gear

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5718774A (en) * 1995-07-27 1998-02-17 Nissan Motor Co., Ltd. Method of producing bevel gear
DE19734563C1 (de) 1997-08-04 1998-12-03 Mannesmann Ag Verfahren zur Herstellung von Wälzlagerringen aus Stahl
DE10065737A1 (de) 1999-12-31 2001-07-12 Dana Corp Induktionsgehärtetes geschmiedetes (Zahrad-) Getriebe und Verfahren zum Vorbereiten desselben
US6315841B1 (en) * 1999-12-31 2001-11-13 Dana Corporation Induction hardened forged gear and process for preparing same
JP5405325B2 (ja) * 2010-01-04 2014-02-05 新日鐵住金株式会社 差動歯車およびその製造方法
DE102012017525A1 (de) 2011-09-10 2013-03-14 Volkswagen Aktiengesellschaft Verfahren zur umformenden Herstellung eines Zahnrads mit Außenverzahnung, sowie nach diesem Verfahren herstellbares Zahnrad mit Außenverzahnung
US20160361784A1 (en) 2015-06-15 2016-12-15 American Axle & Manufacturing, Inc. Net forged spiral bevel gear

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
"Heat Treating of Irons and Steels", 1 October 2014, ASM INTERNATIONAL, ISBN: 978-1-62708-168-9, article SAHAY SATYAM S. ET AL: "Heat Treatment of Steel Gears", pages: 204 - 218, XP055930954, DOI: 10.31399/asm.hb.v04d.a0005987 *
BEHRENS BERND-ARNO ET AL: "Microstructural Evolution and Mechanical Properties of Hybrid Bevel Gears Manufactured by Tailored Forming", METALS, vol. 10, no. 10, 13 October 2020 (2020-10-13), pages 1365, XP055930915, DOI: 10.3390/met10101365 *

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