Advanced Material Studies for Additive Manufacturing in terms of Future Gear Application

Abstract

Additive manufacturing by laser beam melting is predestined for complex component geometry like integrated cooling channels without enormous posttreatment processing. To investigate the influence of build-up direction in terms of later tooth excitation of gear-wheels, first fundamental material analyses were accomplished in this publication. Therefore, additively produced specimens were used to determine the build-up direction dependent elastic properties of the material in all three spatial directions based on tensile and torsion tests. The anisotropies of elastic limits and breaking points of previous studies were confirmed in this paper. Furthermore, torsion values were also determined depending on build-up direction. Laser beam melted X3NiCoMoTi18-9-5 (hotwork tool steel) was shown to exhibit extremely high performance under shear loading in comparison to conventionally processed steel. The influence of build-up direction on torsional strength was also shown.

Metal Additive Manufacturing (MAM) Applications in Production of Vehicle Parts and Components—A Review

“…By using appropriate structures, it is possible to produce lightweight gears while still maintaining the required strength properties [95,96]. Additive manufacturing techniques can facilitate the production of internal channels, which may enhance heat dissipation and ensure sufficient lubrication of friction surfaces [97,98]. Figure 13 shows an example of a gear produced using the SLM technique and SS-316L steel [89].…”

Bending Fatigue Behavior of 17-4 PH Gears Produced by Additive Manufacturing

“…With a specific focus on metallic AM gears, in [7] a methodology to realize a lightweight gear by modifying the gear body is proposed. A tooth lightweight design is proposed in [8], in [9,10] a gear with internal cooling channel is shown, and in [11] the gear Noise Vibration Harshness (NVH) behavior and weight optimization by replacing a full gear body with a lattice structure is reported. Moreover, in [4] the design of a gearbox in which gears are produced by using AM technology is presented.…”

Generative design method for lattice structure with hollow struts of variable wall thickness

“…Additive manufacturing (AM) has been defined as a process of joining materials to make an object from three-dimensional (3D) model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. 1,2 The recent improvement of AM technologies have allowed designers to directly manufacture structures of almost arbitrary shapes based on 3D digital model, which expands the design space greatly. 3,4 Owing to the characteristics of good energy absorption, strong thermal, and acoustic insulation properties, and most importantly, a high strength to low mass correlation, lattice structures have attracted wide attention of designers among the numerous types of complex structures.…”