TAILIEUCHUNG - Surface densified camshaft gear for high performance combustion engines

1. Background of the Development The shape of gears is very attractive to the PM manufacturing process. Spur gears as well as helical gears can be shaped by compaction. The performance of gears is influenced beneath the geometrical design mainly by the material parameters tooth root strength σFE and pitting resistance σHlim. The comparison of these values from PM gears to wrought steel gears shows clearly, that PM gears can only be used in low loaded applications (Fig. 1). | Surface densified camshaft gear for high performance combustion engines 1. Background of the Development The shape of gears is very attractive to the PM manufacturing process. Spur gears as well as helical gears can be shaped by compaction. The performance of gears is influenced beneath the geometrical design mainly by the material parameters tooth root strength oFE and pitting resistance oH im. The comparison of these values from PM gears to wrought steel gears shows clearly that PM gears can only be used in low loaded applications Fig. 1 . Dynamic Material properties acc. DIN 3990 Tooth root strength sFE Pitting resistance sHlim Fig. 1. Tooth root strength and pitting resistance 1 The main influence to the differences in mechanical properties has the residual porosity which is caused by the PM manufacturing process. The porosity is distributed in the whole volume of the part. But the stress analysis of torque loaded gears shows that the hot spots always appear near the surface of the tooth Fig. 2 . This leads to the approach to reduce the porosity in the area near the surface. Stress distribution of torque loaded gears In extensive investigations it was able to show that the surface-near areas of PM gears can be densified by a rolling process after sintering Fig. 3 . Fig. 3 Rolling process and cross section of a rolled PM tooth The influence of the densified surface layer to the performance of the gear was investigated at the FZG in Munich. The results are added in the following diagram Fig. 4 Dynamic properties acc. DIN 3990 Tooth root strength sF Pitting resistance sHlim Fig. 4. Tooth root strength and pitting resistance including DENSGRAD TM values. Based on this extraordinary improvement the PM DENSGRAD TM technology is in the position to substitute wrought steel gears keeping the existing space. 2. Gear Design by DENSGRAD TM technology In the course of technical modification of an existing diesel engine Fig. 5 we were asked if the two steel gears which

• Tiếng Anh thương mại
• Surface
• densified
• camshaft
• gear for high performance
• combustion engines
• Dynamic Material properties
• Response surface and artificial neural network prediction model
• Optimization for surface roughness in machining
• Optimization for surface roughness
• Response surface model
• ANN prediction model sufficiently predict
• Irrigation water quality
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• Kinematic Geometry of Surface Machining
• author of Kinematic Geometry of Surface Machining
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• differential geometry
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• Cutting forces in hard turning by PVD coated insert
• PVD coated insert
• Coated ceramic insert
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• Modeling of surface roughnes
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