19FTM16. Material Properties and Tooth Root Bending Strength of Shot Blasted, Case Carburized Gears With Alternative Microstructures
19FTM16. Material Properties and Tooth Root Bending Strength of Shot Blasted, Case Carburized Gears With Alternative Microstructures
19FTM16. Material Properties and Tooth Root Bending Strength of Shot Blasted, Case Carburized Gears With Alternative Microstructures
Material Properties and Tooth Root Bending Strength of Shot Blasted, Case Carburized Gears with
Alternative Microstructures
Author: Karl Jakob Winkler, Christian Güntner, Thomas Tobie, Karsten Stahl, and Stefan Schurer
Case hardening is one of the most common heat treatment processes for highly loaded components such as
shafts and gears. Due to numerous investigations and according to the material requirements for quality grade
MQ and ME in part 5 of ISO 6336, a microstructure consisting of martensite with less than 30% retained austenite
is favorable for a high load carrying capacity.
A former research project focused on the load carrying capacity of carbonitrided gears with alternative
microstructures. In this research project, the carbonitrided gears with an increased amount of retained austenite of
up to 65% showed a higher tooth flank load capacity than standard case carburized gears. At the same time, the
tooth root bending strength was not influenced in a negative way. The question arises, how different alternative
microstructures influence material properties and thus affect the tooth root bending strength of gears.
This report states the results of current investigations on material properties such as hardness depth profile,
residual stress condition and amount of retained austenite as well as the tooth root bending strength of gear
variants with different alternative microstructures. All gear variants are shot blasted after the heat treatment and
made out of the materials 20MnCr5 and 18CrNiMo7-6.
The tooth root bending strength in the high cycle fatigue regime of these gear variants is not inferior compared to
standard case carburized gears. In the cycle regime of limited life, the tooth root bending strength can be
increased as well as decreased by the alternative microstructures.
As consequence, when regarding the tooth root bending strength, certain alternative microstructures, which are
different to the recommendations of part 5 of the standard ISO 6336, can be tolerated. This means consequently,
that if the tooth root bending strength is tested and acceptable, alternative microstructures can increase the tooth
flank load capacity for shot blasted, case carburized gears.
ISBN: 978-1-64353-055-0
19FTM17. Chamfering of Cylindrical Gears - New Innovative Cutting Solutions for Efficient Gear Production
Author: Gottfried Klein
Cylindrical gear chamfering and deburring is a rather ‘unloved’ process that adds cost but without delivering
readily apparent improvements in gear quality. However, the chamfer process, when performed correctly,
provides significant advantages for downstream handling and processing. This is why manufacturers of
automotive- and truck-sized gears are increasingly exploring new technologies to chamfer their gears.
Two major chamfer technologies are used: forming and cutting. While chamfer rolling is a highly proven forming
process that has been used for decades mainly in mass production, cutting chamfer technologies are of
increasing market interest due to cost reduction and increased quality requirements; especially in dry cutting
conditions.
This paper will cover new chamfer cutting processes: Chamfer Contour Milling and Chamfer Hobbing and
compare them with the existing chamfer roll technology.
Chamfer Contour Milling uses a universal fly cutter tool with indexable carbide inserts. Chamfer angle and
chamfer size depend on programmable machine movements. Therefore, this process provides highest flexibility
for coarse pitch gears – even with different modules, pressure angles or number of teeth.
Chamfer Hobbing has been developed for modern gear production focusing on low tool cost per part with dry
cutting and short cycle times in mass production. As for the left and right gear flank, separate and dedicated
chamfer hobs are used to meet most customer specifications in the market.
By comparing the advantages and limits of the aforementioned chamfer processes in gear production for
workpieces up to 400 mm diameter and module 8 mm, it is possible to select the right process depending on the
specific requirements.
ISBN: 978-1-64353-056-7
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