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Powder Metal Magic Design Innovations in PM Applications Matthew Jaster, Associate Editor Capstan Atlantic, located in Wrentham, Massachusetts, produces powder metal gears, sprockets and complex structural components. The company has provided unique powder metal products in a variety of industries including automotive, business machines, appliances, lawn and garden equipment and recreational vehicles. The recent resurgence of the automotive industry has played a large role in increasing opportunities in powder metal, particularly in areas like suspension, powertrain, steering column and electronic power steering (EPS). Richard Slattery, vice president of engineering at Capstan Atlantic, recently discussed some of the latest powder metal gear designs that are more cost effective compared to their cut steel alternatives. 52 GEARTECHNOLOGY August 2012 www.geartechnology.com
Automotive Application A helical/spur combination gear— where all gear data is relative to the journal diameters, rather than an inside diameter—was utilized for a power liftgate application. The elemental gear data is very precise to enable quiet gear performance as NVH (noise, vibration and harshness) thresholds are very sensitive to the end user. In order to function properly, the gear must run quietly. The part is compacted using two lower and upper punches, coupled with a proprietary helical bearing system to allow punches to spin freely under 45 tsi of pressure. (Ed’s note: See sidebar page 57 for more information). A custom designed robotic material handling system is used to remove parts from the press and place them in sinter carriers. The pinion and gear have very precise elemental gear tolerances. The significant process control challenge is that all the gear data is measured relative to the central axis of the part as established by the two opposing journal diameters. This presents challenging tool setup requirements as well as special fixturing for part measurement. The material is an FC 0208-50 (copper steel) with a nominal density of 6.85 g/cm 3 and a typical hardness of HRB 75, a yield strength of 55,000 psi and a tensile strength of 65,000 psi. “This near-net-shape process is highly cost competitive versus other metalworking/gear manufacturing processes associated with this level of precision,” Slattery says. “The part offers precise elemental gear tolerances for system noise reduction, without an inside diameter as a datum.” A net-shaped PM clutch hub combines multi-level technology, an innovative material system and a unique PM processing method (courtesy of Capstan Atlantic). Lawn and Garden Application A high precision, copper infiltrated, helical gear was needed for a two-cylinder engine application in the lawn and garden market. “This copper infiltrated helical crankshaft gear is compacted with a custom geometry to allow for subsequent gear tooth modification for high strength and minimum noise,” Slattery says. The gear offers a 25.5 degree helix angle, a custom involute profile that includes tip relief and a “mirror like” surface finish on the tooth flanks. The teeth have a maximum helix error www.geartechnology.com August 2012 GEARTECHNOLOGY 53
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Page 38 and 39: able for the machining of workpiece
Page 40 and 41: See Drake’s newest External Threa
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Page 44 and 45: More Than Machines, • BMS Electro
Page 46 and 47: BRIGHT IDEAS, BRILLIANT SOLUTIONS A
Page 48 and 49: A S K T H E E X P E R T Got a Gear
Page 50 and 51: A S K T H E E X P E R T profile shi
Page 52 and 53: A S K T H E E X P E R T external ge
Page 56 and 57: This helical/spur combination gear
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Page 60 and 61: Foreground: Medical introducer part
Page 62 and 63: High-Performance Sintered-Steel Gea
Page 64 and 65: Figure 3—Rolling contact fatigue
Page 66 and 67: tance, a surface-densification tech
Page 68 and 69: Case Study Involving Surface Durabi
Page 70 and 71: Figure 4—Baseline Gear A, Mesh 1,
Page 72 and 73: Table 3—Roughness parameters of b
Page 74 and 75: Figure 17—ISF Gear A, Mesh 1: pos
Page 76 and 77: Table 9—Design requirements for I
Page 78 and 79: N E W S In Memoriam James J. Cervin
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Page 90 and 91: A D D E N D U M Technology Mash-Up
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