FE-Based Design of a Forging Tool System for a Hybrid Bevel Gear

Behrens, Bernd‐Arno; Bouguecha, Anas; Bonk, Christian; Bonhage, Martin; Chugreeva, Anna; Matthias, Thorsten

doi:10.4028/www.scientific.net/kem.742.544

Cited by 6 publications

(3 citation statements)

References 12 publications

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“…However, the presence of pores is the greatest risk of failure during operation on the microstructure regarding tribologically loaded components reinforced by PTA cladding without subsequent forming [4]. In the work of Behrens et al [5], a numerical tool system was designed to produce hybrid bevel gears by tailored forming, which had previously been joined by deposition welding. In addition to the numerical process design, the necessary material characterization, the first results of the experimental forging investigations as well as the resulting metallographic analyses were presented.…”

Section: Process Chain For the Manufacture Of A Hybrid Axial Bearing mentioning

confidence: 99%

Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Behrens

Chugreev

Matthias

et al. 2019

Metals

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Components subject to rolling contact fatigue, such as gears and rolling bearings, are among the fundamental machine elements in mechanical and vehicle engineering. Rolling bearings are generally not designed to be fatigue-resistant, as the necessary oversizing is not technically and economically marketable. In order to improve the load-bearing capacity, resource efficiency and application possibilities of rolling bearings and other possible multi-material solid components, a new process chain was developed at Leibniz University Hannover as a part of the Collaborative Research Centre 1153 “Tailored Forming”. Semi-finished products, already joined before the forming process, are used here to allow a further optimisation of joint quality by forming and finishing. In this paper, a plasma-powder-deposition welding process is presented, which enables precise material deposition and control of the welding depth. For this study, bearing washers (serving as rolling bearing raceways) of a cylindrical roller thrust bearing, similar to type 81212 with a multi-layer structure, were manufactured. A previously non-weldable high-performance material, steel AISI 5140, was used as the cladding layer. Depending on the degree of forming, grain-refinement within the welded material was achieved by thermo-mechanical treatment of the joining zone during the forming process. This grain-refinements lead to an improvement of the mechanical properties and thus, to a higher lifetime for washers of an axial cylindrical roller bearing, which were examined as an exemplary component on a fatigue test bench. To evaluate the bearing washers, the results of the bearing tests were compared with industrial bearings and deposition welded axial-bearing washers without subsequent forming. In addition, the bearing washers were analysed micro-tribologically and by scanning acoustic microscopy both after welding and after the forming process. Nano-scratch tests were carried out on the bearing washers to analyse the layer properties. Together with the results of additional microscopic images of the surface and cross-sections, the causes of failure due to fatigue and wear were identified.

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Section: Process Chain For the Manufacture Of A Hybrid Axial Bearing mentioning

confidence: 99%

Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Behrens

Chugreev

Matthias

et al. 2019

Metals

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“…In the case of CWR, the workpiece rotates around its own axis while the tools move transversely to it. The tools are wedge-shape profiled and create a mass distribution along the axis of rotation of the workpiece [9]. Kruse et al investigated the joining zone displacement in serially arranged hybrid parts [10].…”

Section: Research On Hybrid Materials and Inhomogeneous Heatingmentioning

confidence: 99%

Contact Temperature Measurements on Hybrid Aluminum–Steel Workpieces in a Cross-Wedge Rolling Process

Merkel

Kruse

Kriwall

et al. 2023

JMMP

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The Collaborative Research Center 1153 is investigating a novel process chain for manufacturing high-performance hybrid components. The combination of aluminum and steel can reduce the weight of components and lead to lower fuel consumption. During the welding of aluminum and steel, a brittle intermetallic phase is formed that reduces the service life of the component. After welding, the workpiece is heated inhomogeneously and hot-formed in a cross-wedge rolling process. Since the intermetallic phase grows depending on the temperature during hot forming, temperature control is of great importance. In this paper, the possibility of process-integrated contact temperature measurement with thin-film sensors is investigated. For this purpose, the initial temperature distribution after induction heating of the workpiece is determined. Subsequently, cross-wedge rolling is carried out, and the data of the thin-film sensors are compared to the temperature measurements after heating. It is shown that thin-film sensors inserted into the tool are capable of measuring surface temperatures even at a contact time of 0.041 s. The new process monitoring of the temperature makes it possible to develop a better understanding of the process as well as to further optimize the temperature distribution. In the long term, knowledge of the temperatures in the different materials also makes it possible to derive quality characteristics as well as insights into the causes of possible process errors (e.g., fracture of the joining zone).

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“…Within the studied gear component, a highly effective plastic strain of approx. 2 within the welded casing and prevailing compressive stress states, which a typically for closed die hot forging processes [21], contribute to an intensive dynamic recrystallization and pore healing of the coarse welding microstructure. The positive influence of forming has already been demonstrated in previous studies on hybrid blanks in cross wedge rolling [22,23].…”

Section: Deposition Weldingmentioning

confidence: 99%

Manufacturing of High-Performance Bi-Metal Bevel Gears by Combined Deposition Welding and Forging

Chugreeva

Mildebrath

Diefenbach

et al. 2018

Metals

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The present paper describes a new method concerning the production of hybrid bevel gears using the Tailored Forming technology. The main idea of the Tailored Forming involves the creation of bi-metal workpieces using a joining process prior to the forming step and targeted treatment of the resulting joint by thermo-mechanical processing during the subsequent forming at elevated temperatures. This improves the mechanical and geometrical properties of the joining zone. The aim is to produce components with a hybrid material system, where the high-quality and expensive material is located in highly stressed areas only. When used appropriately, it is possible to reduce costs by using fewer high-performance materials than in a component made of a single material. There is also the opportunity to significantly increase performance by combining special load-tailored high-performance materials. The core of the technology consists in the material-locking coating of semi-finished parts by means of plasma-transferred-arc welding (PTA) and subsequent forming. In the presented investigations, steel cylinders made of C22.8 are first coated with the higher-quality heat-treatable steel 41Cr4 using PTA-welding and then hot-formed in a forging process. It could be shown that the applied coating can be formed successfully by hot forging processes without suffering any damage or defects and that the previous weld structure is completely transformed into a homogeneous forming-typical structure. Thus, negative thermal influences of the welding process on the microstructure are completely neutralized.

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FE-Based Design of a Forging Tool System for a Hybrid Bevel Gear

Cited by 6 publications

References 12 publications

Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Contact Temperature Measurements on Hybrid Aluminum–Steel Workpieces in a Cross-Wedge Rolling Process

Manufacturing of High-Performance Bi-Metal Bevel Gears by Combined Deposition Welding and Forging

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