Download the August 2012 Issue in PDF format - Gear Technology ...
Download the August 2012 Issue in PDF format - Gear Technology ... Download the August 2012 Issue in PDF format - Gear Technology ...
This helical/spur combination gear is utilized in a power liftgate actuator application (courtesy of Capstan Atlantic). (lead) of 15 microns and a profile error of less than 30 microns. Additionally, this gear has an accurately machined inside diameter (24 microns total tolerance) and locating face, enabling precise assembly. The gear requires a high level of tool geometry control along with minimum weight and sectional density variation at a compact and very consistent sinter temperature profile. The inside diameter is then precision machined and the teeth are rolled for densification and final qualification of the gear geometry. The material is an FX 1008-50 (copper infiltrated steel) at a 7.3 g/cm 3 minimum density and apparent hardness of RB 90. The elongation exceeds three percent and the impact strength exceeds 15J (10 ft-lbs). This elongation enables very high press fit interference on the mating crankshaft to eliminate the potential of gear slippage in service. The tensile strength of this material is > 600 MPa (90,000 psi). This gear’s as-sintered, near-net shape and its physical strength, along with precise dimensional control, replace a far more expensive wrought IMTS BOOTH # N-6668 54 GEARTECHNOLOGY August 2012 www.geartechnology.com
steel alternative, offering a 35 percent cost reduction. “This gear has successfully passed all levels of endurance testing in this two-cylinder industrial engine application,” Slattery says. “It’s economically attractive, highly precise and costs almost fifty percent less than the cut steel alternative.” Industrial Application A net-shaped PM clutch hub replaces a machined alternative that is more expensive. It combines multi-level technology, an innovative material system and a unique PM processing method. The part is compacted using four lower and a stepped single upper punch, coupled with an enhanced powder feed system to facilitate equalized local densities. Additional proprietary tool material and treatment systems are used to enable long, thin punches to withstand extreme tonnage. This is a complex, multi-level, higher dense component, capable of withstanding very high torque loads in service. The part is provided net shape, in the assintered/shot peened condition, replacing a previously machined version. “The functionality of this hub requires very close relationships between the five diameters,” Slattery says. “The tooth run-out to the internal spline is less than 100 microns (0.1 mm).” The process control of the part is the consistent dimensional change for all levels through the sintering operation. This control is maintained by achieving sectional density variation within 0.05 g/cm 3 at the compaction step in the process. The material is a hybrid Fe/Mo/Cu/C alloy with very good yield strength and as-sintered tensile properties. The flange of this component is subjected to repetitive bending fatigue in service. Therefore, the ability to achieve the required strength, as well as the bending fatigue resistance, is the key to the field success of this component. “Simply put, this PM part offers precision, economic value and strength,” Slattery adds. Appliance Application A complex, off-center-loaded PM rack has multiple lower levels, one of which is formed on the core rod platen and a dual upper punch system. Special robotic automation is required to remove the part from the lower tooling, flip it 180 degrees and place it on a special conveying system. “This is a seven level part requiring six punches. The rack system incorporates a progressive variable tooth space to compensate for system tooth engagement variation in service. The U slot density is controlled through off standard power distribution by the dual upper punches,” Slattery says. He continues, “This rack’s as-sintered, near-net shape and its physical strength along with precise dimensional control, replace a far more expensive die cast alternative (a 38 percent cost reduction).” The engineering properties include a highly controlled rack tooth profile and spacing characteristics. Perpendicularity of U slot to opposing locating surface is critical along with the flatness of the locating surface. This part requires a high level www.geartechnology.com August 2012 GEARTECHNOLOGY 55
- Page 5 and 6: Customers Say it Best We are extrem
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- Page 10 and 11: Our Technologies, Your Tommorow The
- Page 12 and 13: V O I C E S Adapting Lean for High-
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- Page 16 and 17: P R O D U C T N E W S New Technolog
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- Page 20 and 21: P R O D U C T Dudley’s Handbook o
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- Page 28 and 29: IMTS 2012 Alphabetical Listings COM
- Page 30 and 31: IMTS 2012 Product Preview Star SU B
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- Page 34 and 35: Kapp Technologies Booth N-7036 Two
- Page 36 and 37: different grinding wheels in one se
- 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 54 and 55: Powder Metal Magic Design Innovatio
- Page 58 and 59: of tooth geometry control along wit
- 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
- Page 80 and 81: N E W S In her new role, Codina is
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- Page 90 and 91: A D D E N D U M Technology Mash-Up
- Page 92: HÖFLER by KLINGELNBERG: Gear Hobbi
This helical/spur comb<strong>in</strong>ation gear is utilized <strong>in</strong> a power liftgate actuator application<br />
(courtesy of Capstan Atlantic).<br />
(lead) of 15 microns and a profile error<br />
of less than 30 microns. Additionally,<br />
this gear has an accurately mach<strong>in</strong>ed<br />
<strong>in</strong>side diameter (24 microns total tolerance)<br />
and locat<strong>in</strong>g face, enabl<strong>in</strong>g precise<br />
assembly.<br />
The gear requires a high level of tool<br />
geometry control along with m<strong>in</strong>imum<br />
weight and sectional density variation<br />
at a compact and very consistent s<strong>in</strong>ter<br />
temperature profile. The <strong>in</strong>side diameter<br />
is <strong>the</strong>n precision mach<strong>in</strong>ed and <strong>the</strong><br />
teeth are rolled for densification and<br />
f<strong>in</strong>al qualification of <strong>the</strong> gear geometry.<br />
The material is an FX 1008-50<br />
(copper <strong>in</strong>filtrated steel) at a 7.3 g/cm 3<br />
m<strong>in</strong>imum density and apparent hardness<br />
of RB 90. The elongation exceeds<br />
three percent and <strong>the</strong> impact strength<br />
exceeds 15J (10 ft-lbs). This elongation<br />
enables very high press fit <strong>in</strong>terference<br />
on <strong>the</strong> mat<strong>in</strong>g crankshaft to elim<strong>in</strong>ate<br />
<strong>the</strong> potential of gear slippage <strong>in</strong> service.<br />
The tensile strength of this material<br />
is > 600 MPa (90,000 psi).<br />
This gear’s as-s<strong>in</strong>tered, near-net<br />
shape and its physical strength, along<br />
with precise dimensional control,<br />
replace a far more expensive wrought<br />
IMTS BOOTH #<br />
N-6668<br />
54<br />
GEARTECHNOLOGY <strong>August</strong> <strong>2012</strong> www.geartechnology.com
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