alternative and new ways of production for gear manufacturing · • electrical discharge machining...

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Alternative and new ways of production for gear manufacturing Prof. Dr. Ir. Bert LAUWERS Dean | Faculty of Engineering Technology Departement Mechanical Engineering | Research Group “Advanced Manufacturing Processes” [email protected] EUROTRANS Gear Training on ‘Production’ 25 February – 1 March | 2019

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Page 1: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

Alternative and new ways of production for gear manufacturing

Prof. Dr. Ir. Bert LAUWERSDean | Faculty of Engineering TechnologyDepartement Mechanical Engineering | Research Group “Advanced Manufacturing Processes” [email protected]

EUROTRANS Gear Training on ‘Production’25 February – 1 March | 2019

Page 2: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Full Professor KU Leuven• Dean | Faculty of Engineering Technology• Research & Education

• Advanced Manufacturing Processes(Department Mechanical Engineering)

• Cooperations• Member FlandersMake• Sirris

Who I am ?

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

2Research Group “Advanced Manufacturing”

Department of Mechanical Engineering Faculty of Engineering Technology

Page 3: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Research• Process• Digital Manufacturing

(Control & CAD/CAM)

Manufacturing Processes @ KU Leuven

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Manufacturing Processes

Additive Manufacturing

(AM)

Subtractive & Hybrid

Processes

Micro & Precision

Flexible Sheet Manufacturing

Lifecycle Engineering

Metrology & Quality Control

Page 4: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Subtractive & Hybrid Processes

• Processes: Multi-axis machining, EDM, ECM, Hybrid Processes,..

• Materials:Advanced alloys, carbides, ceramics

• Digital ManufacturingAdvanced Tool path generation, Process Planning,..

My research

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Machining of (complex shaped) components in either soft or hard

materials

Page 5: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Common technologies for gear manufacturing• Other technologies

• Electrical Discharge Machining (EDM)• Multi-axis machining• Additive Manufacturing technologies• Combinations

• Commercial systems | Solutions• Process chains for fast (low series) gear manufacturing

• One day production of single gears

• Gear manufacturing in advanced materials (e.g.Ceramics)

• Technologies for micro gear manufacturing

Course content

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Principles & TechnologyTest case

Page 6: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

Common technologies for gear manufacturing

6Research Group “Advanced Manufacturing Processes”

Department of Mechanical Engineering

Page 7: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Common technologies

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 8: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Generative methods

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Hobbing• Shaping

Page 9: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Non-generative methods

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Broaching• Milling

Page 10: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Stamping,..

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Forging• Stamping• Casting• Powder

MetallurgyTechniques

• InjectionMoulding

Page 11: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Finishing

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Shaving• Grinding• Honing

Page 12: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• New production methods for functional gear prototypes and small series production

• Machine tool manufacturers and CAD/CAM software providers moving towards new and flexible solutions forgear manufacturing

Trends…

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 13: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

Other technologies

13Research Group “Advanced Manufacturing Processes”

Department of Mechanical Engineering

Page 14: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Objectives/requirements• Resulting shape accuracy should be comparable to

conventional series production processes• Surface roughness within required specifications• Same or better surface/material integrity (stresses,

hardness,…)• Increasing productivity & flexibility

• Omit the need for dedicated tools• Flexible setup (easy to adopt to different gear designs)• …

Application of other technologies…

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 15: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Electrical Discharge Machining• (Multi-axis) Milling• Additive Manufacturing

• Research carried out in the frame of various projects, supported by VLAIO

• “Precision Manufacturing for new and better products”

• ‘INTLAS’ Integrated Laser Hardening

Technologies discussed…

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 16: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Electrical Discharge Machining (EDM)

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

servo feedcontrol

generator

fluiddielectric

tool

workpiece

+

-

gape-

ions

dielectric

moltenmaterial

moltenmaterial 1. Ingnition phase

2. Melting phase3. Implosion

Page 17: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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EDM – configurations

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Sinking EDM Milling EDM Wire EDM

Page 18: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• (+)• Machining of hard materials

• High alloyed steels, ceramics,…• High dimensional tolerances • Surface roughness values (< 0,5µm Ra)

• (-)• Process speed• HAZ

EDM – process characteristics

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 19: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Wire EDM• Wire ∅: 50…300µm

EDM & gear manufacturing

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 20: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Die sinking EDM• Machines are fully NC-controlled• 4-axis• Special strategies for gear manufacturing

EDM & gear manufacturing

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 21: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• EDM milling• Use of standard tubular electrodes

• Similarity with milling operations

EDM & gear manufacturing

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 22: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Material removal by moving milling cutters

• Tool geometries• Ball nose cutters• End mill cutters• ….

NC-milling

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 23: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Strategies• Contouring

• 3-axis / multi-axis• Using flank of cutter

• Cavity milling• 2D/2,5D• Tools

• End mills (OK)• Ball nose ( step-over !!!!)

NC-milling

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 24: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Strategies• Machining of complex shapes | cavities

• Pre-machining by cavity machining• Finishing

• Using ball nose cutters• 3-axis• Multi-axis

• Using end-mill cutters• Multi-axis !!!!

NC-milling

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

v

u

Page 25: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Various methods (SLM, FDM, cladding,…)• Various materials (plastics, metals,..)

• Selective Laser Melting most potential

Additive Manufacturing

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Slicing Layer by layer

Page 26: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• (+)• ‘High’ accuracy (among the AM

methods !!!!)• Various materials available &

technologies developed• Dense products• Simple & easy programming

• (-) • Slow building process• Residual (thermal) stresses

Selective Laser Melting

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 27: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Mold inserts with cooling channels

• Built-in heat exchanger

• Medical

• Gears ?

SLM - Applications

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 28: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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CAD/CAM & machine programming

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Process planning

NC-postprocessor

NC-program(ISO-code)

CL-Data

CAD

CAM

IGES, STEP, STL

CAM (AM)Slicing & scanning

Page 29: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

Other technologiesTest case - Comparison

29Research Group “Advanced Manufacturing Processes”

Department of Mechanical Engineering

Page 30: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Test Case

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Test case gear dataMaterial 16MnCr5Number of teeth (Z) 36Heigth 31.5 [mm]Normal module (mn) 2.120 [mm]Reference circle diameter (d0) 76.320 [mm]Base circle diameter (db) 72.985 [mm]Crowning width of tooth (cβ) 0.008 +/- 0.003 [mm]Gear quality Acc. To DIN 3960DIN Class 6Surface finish (Ra) 0.8 [µm]Profile angle variation fHα 6 [µm]Profile form variation ff 8 [µm]Total profile variation Ff 10 [µm]Tooth trace angle variation fHβ 12 [µm]Total tooth thrace variation Fβ 15 [µm]Tooth trace form variation Fβf 9 [µm]Run out Fr 24 [µm]Cumulative pitch error Fp 32 [µm]Single pitch error fp 7 [µm]Pitch to pitch error fu 9 [µm]

Page 31: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Gear Quality parameters

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Source: Wenzel

Page 32: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Wire EDM – set-up

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Wire EDM

Page 33: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Wire EDM – Machining procedure

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

(A)

(D)

(C)

(B)

(A) Machined holder

(B) Gear Blank gluedon holder

(C)Gear machinedexcept few toothtips

(D)Gear removed fromholder, rotated 10°, glued back forremovingremaining tips

Page 34: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Setup• Sodick AQ 537L wire-EDM• Water based dielectric• 1 Main cut and 4 trim cuts• Ø 0.25 mm brass wire

• Surface roughness• Main cut: 3 µm Ra• Final trim cut: 0.42 µm Ra

Wire EDM - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Klink, A., Guo, Y.B., Klocke, F., 2012, “Surface integrity evolution of powder metallurgicaltool steel by main cut and finishing trim cuts in wire- EDM”, 1st CIRP Conf. On Surface Integrity (CSI)

Page 35: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Wire EDM - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Task Time [min]CAM programming 90Manufacturing of the tool holder 200Positioning and gluing 15Main cut 400Trim cut 530Repositioning and gluing 15Removing of the remaining tips 70Total machining time 1320

Gear quality parameter Measured value [µm]

Limit [µm]

Surface finish (Ra) 0.4 0.8Profile angle variation fHα 0.6 6Profile form variation ff 1.9 8Total profile variation Ff 2.3 10Tooth trace angle variation fHβ -31.9 12Total tooth trace variation Fβ 31.6 15Tooth trace form variation Fβf 0.5 9Run out Fr 9.4 24Cumulative pitch error Fp 6.8 32Single pitch error fp 3.5 7Pitch to pitch error fu 5.9 9

• Trace angle variation out of tolerance wobble• Excellent gear quality, however limited flexibility (ruled surfaces)

Page 36: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Wire EDM - possibilities

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Tip Relief

Root Relief

Angular Profile Variance

Profile Crowning

• Possible: • Tip relief, root relief, angular profile variance, profile crowning

Page 37: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Wire EDM - possibilities

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Might be possible (further research required):

• angular lead variance, end relief

• Not possible: lead crowning, helical gears

Helical Gear Angular Lead Variance

Lead CrowningEnd Relief

Page 38: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Multi-axis milling (4-axis)

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 39: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Multi-axis milling (4-axis)

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

1) Contour 12 mm end mill 2) Profile 3 mm end mill8000 rpm, 280 mm/min

3) Profile 2 mm end mill12000 rpm, 320 mm/min

4) Profile 2 mm ball mill16000 rpm, 640 mm/min

Page 40: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Surface roughness

• Tooth trace angle variation fHβ = 59.5 µm Ensured good parallelism of XY plane machine and gear blank fHβ = 4.1µm

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

No. of passes 150 250 400 450 500 550Surface roughness Ra [µm] 0.76 0.38 0.27 0.21 0.24 0.22Required roughness Ra [µm] 0.8

Page 41: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Flank quality – influence of milling strategy

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Right flank quality <<left flank quality

( )

Pull

Left Right RightLeft

( )

PushPull Pull

Page 42: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Quality - Repetitive pitch error• Individual pitch error in the order of a few microns, which add up

!!!!

• Possible reasons ?• Stiffness of the machine tool set-up ?

• Influence tool holder• Stiffness of the clamping set-up

• CAD NC errors ?• Temperature stability ?• Sequence of operations ?• …..

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

40 µm

Page 43: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Quality - Repetitive pitch error• Influence of the tool holder

• Before

• New tool holder system • Tool length with less overhang, shrink holder

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

40 µm

20 µm

Page 44: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Quality - Repetitive pitch error • Stifness clamping ?

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Radialdisplacement

in µm at R=100mm

Rotational force/moment in Nm

10 20 30 40 50 60 70

Cla

mpi

ngfo

rce

in N

m 20 2 8 55 140 180 180 18030 3 5 13 40 135 170 14540 2 3 6 8 28 65 15050 3 4 4 5 7 55 10560 2 2 3 3 10 33 75

Page 45: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Quality - Repetitive pitch error • CAD NC link ?

• Tolerances introduced (file generation, Intol/outtol for tool pathgeneration,…)

• Loss of accuracy ?

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

NATIVE Pro-E STEP Siemens NX Heidenhain

CAD CAD CAM Control

Page 46: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Quality - Repetitive pitch error• Temperature stability?

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Time (min.)

Dis

plac

emen

t (µm

)

Page 47: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Quality - Repetitive pitch error• Sequence of operations

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

1 3 5 79

1113

15171921

2325

2729

313335363432302826

2422

2018161412

108 6 4 21 36 3534

3332

3130292827

2625

2423

222120191817161514

1312

1110987

65 4 3 2

Page 48: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Task Time [min]CAM programming & toolpath generation 90Clamping and alignment workpiece 15Roughing 3 mm endmill 60Roughing 2 mm endmill 90Finishing 2 mm ball mill 600Total manufacturing time 855

Gear quality parameter Measured value [µm] Limit [µm]Surface finish (Ra) 0.2 0.8Profile angle variation fHα -4.7 6Profile form variation ff 3.3 8Total profile variation Ff 8.0 10Tooth trace angle variation fHβ 4.1 12Total tooth trace variation Fβ 14.1 15Tooth trace form variation Fβf 2.1 9Run out Fr 16.8 24Cumulative pitch error Fp 18.5 32Single pitch error fp 8.5 7Pitch to pitch error fu 4.0 9

Page 49: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Quality - Single pitch error• Control of tool wear ?• Non-optimal conditions for 3-axis milling with ball nose cutters

• Chaniging process paramters (eg. cutting speed)• Effect on tool wear !!

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering 49

Page 50: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Quality• Alternative milling strategies

use of end-mills constant contact point (& cutting speed) tool axis perpendicular on surface normal in contact point

Multi-axis milling - results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 51: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Program structure

Overall milling strategy

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Tool call• Measuring tool diameter in tool contact point (Blum laser)• Logging tool diameter/tool length• Milling flank right (actual tool diameter)• Milling flank left (actual tool diameter)• Rotation of C-as (delta 10°)• Measuring tool diameter in tool contact point (Blum laser)• Logging tool diameter/tool length• Milling flank right (actual tool diameter)• Milling flank left (actual tool diameter)• Rotation of C-as (delta 10°)• …

Page 52: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• 16MnCr5 • No standard SLM material• But possible [cfr. reserach Kempen et. al]

• However pay special attention to prohibit cracks for carbon richsteels

• Procedure • CAD file preparation (slicing)• SLM process• Postmachining steps

• Wire EDM operation to remove part from base plate• Shot peening to create compressive residual stress

Selective Laser Melting

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 53: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Selective Laser Melting - Results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Gear quality parameter Measured value [µm]

Limit [µm]

Surface finish (Ra) 2.5 0.8Profile angle variation fHα -58.7 6Profile form variation ff 32.8 8Total profile variation Ff 75.2 10Tooth trace angle variation fHβ -49.9 12Total tooth trace variation Fβ 43.2 15Tooth trace form variation Fβf 19.3 9Run out Fr 111 24Cumulative pitch error Fp 133 32Single pitch error fp 29.0 7Pitch to pitch error fu 34.7 9

TaskTime [min]

CAD file preparation (slicing) 30SLM process 840Postmachining 150Total machining time 1020

Page 54: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Wire-EDM• Superior accuracy and good surface quality, “low” flexibility

• SLM• Low surface finish and shape accuracy• Possible as Near Net Shape strategy !

• Multi-axis milling• Accuracy OK: some issues are dealt with, still some

improvement needed• High flexibility (flank corrections, helical gears, double

helical gears,…)

Comparison between various methods

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Machining Technology Machining time [min.] Surface finish Ra [µm] Shape accuracy FlexilbilityMilling ++ ++ + ++Wire-EDM - + ++ -Selective Laser Melting + -- -- ++

Page 55: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

Commercial Systems

55Research Group “Advanced Manufacturing Processes”

Department of Mechanical Engineering

Page 56: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

56

Defawes / Bierens developed a gear milling strategy/software

• Non-CAD model based, but mathematical description based • Only available as service, software/strategy not for sale• Any gear shape possible, for example: own developed S-

shaped gear• 30-35% claimed increase of power transfer• Less heat and noise• No need for axial fixation

Defawes / Bierens

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 57: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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Euklid provides software for toolpathplanning for gear milling

• CAD model based• Special module for gear toolpath

planning

EUKLID Gear CAM

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 58: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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DMG GearMILL is software for toolpath planning for gearmilling by ball end mills

• Only available for DMG machines• Not a lot of non-commercial documentation to be found

DMG GearMILL

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 59: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Software & hardware

• InvoMilling tooling strategy• (+)

• Faster than using end milling strategies• Fast programming using the

accompanying software• (-)

• Less flexible compared to end milling strategies

• Limited quality (up to DIN6)

Sandvik / DMG InvoMilling

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 60: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

Process chains for fast (low series) gear

manufacturing

60Research Group “Advanced Manufacturing Processes”

Department of Mechanical Engineering

Page 61: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Dedicated tools are required for gear production (gearhobbing & grinding)

• 8 weeks lead time, order of dedicated tools

Conventional production

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 62: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Process chain based on turning/milling still quite some logistics

• Conventional hardening strategies:• Carburising• Carbonitriding• Nitriding• ... All require taking out the workpiece, logistics to hardening facility, re-clamping and re-alignment, hard finishing.

Process chain

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Turning / MillingUnclamping + to hardening

setupHardening

re-clamping and re-

alignmentHard finishing

of part

Page 63: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Performing the hardening operation on the machining center

• Possible hardening strategies:• Flame Hardening:

• Less control of hardening, flat surface hardening possible, not veryflexible

• Induction Hardening• Good control of process, not very flexible (electrode is workpiece

shape dependant)• Laser Hardening

• Good control of process, very flexible, very localized heat input

Use of hybrid machine platforms..

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Turning / MillingHardening on

machining center

Hard finishing of part

Page 64: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Principle• Laser heats up the material up to above the Ac3 temperature.

Material is cooled quickly below Ms temperature.• Higher hardness values possible (faster cooling)

(Selective) Laser hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 65: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Tailored hardening possible• Bearing locations on shaft• Active flank of gear teeth• Cutting edge of knife blade• …

• Limited distortions• Localized heat input• Hard finishing operations in a lot of

applications not longer required

(Selective) Laser hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 66: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

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• Technology is certainly not new !• Already implemented for example within robot manipulators

(Selective) Laser hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Page 67: Alternative and new ways of production for gear manufacturing · • Electrical Discharge Machining • (Multi-axis) Milling • Additive Manufacturing • Research carried out in

Process chains for fast (low series) gear

manufacturing

Multi-axis platform for gear manufacturing (with laser integrated hardening)

67Research Group “Advanced Manufacturing Processes”

Department of Mechanical Engineering

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• Integrate hardening operation within in machiningcenter

• Reduce logistics• No unclamping/re-clamping• No re-alignment waste of time and alignment errors• Reduce total lead time

• Integration of Laser• 500W Nd:Yag laser• Laser head developed

@ KU Leuven basedon HSK-63 holder

Objective

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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In operation….

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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Laser head (detail)

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Adapt conventional milling machine to laser operation• Replaced all transparent panels, added safety glass and IP

camera• Added seperate sealable storage unit with automatic tool

changer for storing laser head during milling operation

Implementation on multi-axis platform

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Control system• Allow control of laser by NC-code on 5-axis milling machine• Control storage unit, laser-head tool change• Control power output, feedback from pyrometer

Implementation on multi-axis platform

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Material:• C45 steel (1.0503, EN 10277-2)• Hardness 200 HV

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Variable parameters: • Spotsize diameter (D) [µm] • Traverse speed (v) [mm/min]

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Measured values• Depth of hardening

Vickers micro hardness tests

• Maximum hardnessVickers micro hardness test, average of 2 measurements closest to the surface

• Average measured temperature2 color pyrometer, 50 Hz, averaged in time

• Melted or not Surface roughness comparison before/after laser treatment, every track measured 3 times before and 3 times after hardening. 2-sample t-test, 95% confidence limit

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Depth of hardening

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Depth of hardening – influenced by spotsize and traverse speed, combined factor not significant

• Lower traverse speed and smaller spotsize have a positive effect on the depth of hardened layer

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• Maximum hardness

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Maximum hardness – significantly influenced by spotsize, traverse speed and combined factor

• Smaller spotsize and slower traverse speed have positive influence on maximum hardness

• Combination of large spotsize and fast traverse speed results in dramatically reduction of hardness

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• Melted or not

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

• Melted or not – both spotsize, traverse speed and combined factor are significant

• Only melted when spotsize diameter was small and the traverse speed is low

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• Thermal model• Transient heat transfer model (ABAQUS), 3D thermal solid

elements with 8 nodes• Temperature dependent thermal properties of C45 were used

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Thermal model• 100 mm/min 877°C isotherm

(dashed line) has approximate same size of hardened zone

• A: 1910 µm simulated vs 1885 µm measured

• B: 229 µm simulated vs 210 µm measured

• 400 mm/min max. temperature < 877°C

• Simulated: temperature below ‘critical’ temperature

• Measured: no hardened zone

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Multi-axis milling machine converted to machining center capable of laser hardening

• Full factorial design involving two variable parameters was conducted as a proof of concept

• It can be concluded it is well possible to harden C45 steel from 200HV up to 750HV, on a fully functional 5-axis machining center.

• A transient heat transfer model was successfully applied to simulate the temperature distribution during the hardening process

Integrated laser hardening Conclusion

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Injection molding nozzle made out of Uddeholm Unimax• Conventionally hardened up to 52 HRC (540 HV)

Case study: Injection moulding nozzle

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Hardening strategy tested on thermal model• Hardness values exceeding 840 HV100 (64 HRC) (>52

HRC conventional hardening)• It takes about 7 seconds to harden 1 nozzle!

Case study: Injection moulding nozzle

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Multiple tracks…. (is required for flank hardening of gears)

• Uniform area hardening? • Softening effect !

Technology development | results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• New setup: Scanning hardening on Mori Seiki NTX2000• High speed scanning motion + slow feed

scanning between 50 and 150 Hz

Scanned Laser Hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Mechanical & Optical design

Scanned Laser Hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

FIBER

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Set-up

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Development of optimal scanning strategies• High speed scanning motion + slow feed

scanning between 50 and 150 Hz

Scanned Laser Hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Sinus scanning overheatingat edges

20 mm

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• Sinusoidal scanning motion• Test on ‘laser’-paper

• Low power (20 W), 50 Hz, 1 second (no feed) overheating at the edgesas expected

• Same effect visible on C45 steel (500W, 50 Hz, 100 mm/min feed)

• Optimized scanning function

Scanned Laser Hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Optimized scanning function • Mirror dynamics issue: optimized function

requires to high accelerations

• Frequency limited to 50 Hz and standard triangular shaped motion

• Still melt at edges !

Scanned Laser Hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• 18 mm heat affected zone• Depth of hardened zone:

• 0.2 mm, heat affected zone: 0.3 mm

• Melt at edges

Experimental results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

C45 steel (0,46% C, <0.4% Si, 0.65 Mn, <0.4% Cr)

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Experimental results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Optimized scanning function • Triangular• + Power compensation for reduction of overheating

Scanned Laser Hardening

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Programming strategy: CAM + scanning software• Maintain conventional toolpath planning by CAD/CAM for

industrial applicability

Programming ?

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Developed CAM functionality• Machine movement: straight line• Mirror scanning width: depends on machine position

Programming ?

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Toolpath 1: Machine toolpath Toolpath 2: Scanning contour

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• Developed CAM functionality• Machine movement: straight line• Mirror scanning width: depends on machine position

Programming ?

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

lowered frequency (for illustration)

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Programming for gears

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Pyrometer

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The hardening process

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Temp. setpoint 1300°C, feedrate of 150 mm/min

• Hardness between 600 to 800 HV along gear flank

• Except in “undercut region” hardness 220 HV

• Further improvement• Change inclination angle

Hardening results

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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100 Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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Process chains for fast (low series) gear

manufacturing

Gear manufacturing in advanced materials

101Research Group “Advanced Manufacturing Processes”

Department of Mechanical Engineering

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• Technical ceramics: • Hardness!• Toughness?• Harsh environments!

Ceramics !

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Density [g/cm3]

Hardness HV10 [kg/mm2]

Toughness[Mpa/m1/2] E-modulus [Gpa] EDM-able?

1020 steel 7.87 115 200 yesAL2O3 3.94 1905 4 390 noZrO2-Y 6.00 1200 9 210 noB4C 2.51 2800 3.1 440 yesSiC 3.10 2600 4.6 410 yesSi3N4 3.20 1600 7.5 370 noAlN 3.30 1100 3 331 no

Composites

Zr02-TiN 5.8 1350 9.7 280 yesSi3N4-TiN 3.97 1508 8.7 333 yesAl302-TiCN 4.41 2073 2.66 386 yes

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• Injection molding (followed by sintering)• Series production• Low dimensional accuracy!

Gear manufacturing - ceramics

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Green machining• Easy to machine• Has to be sintered afterwards low dimensional accuracy

(shrinkage)

Gear manufacturing - ceramics

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Machining in sintered state• High dimensional accuracy possible (no more shrinkage)• Very high hardness difficult to machine using conventional

techniques

Gear manufacturing - ceramics

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

UAG

ELID-Grinding

Die sinking EDM

Micro-EDM

Milling

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• Current• Injection molded Yttria stabilized

zirconia

• Other technologies for low series ?• Wire EDM ?• Zr02-TiN (material developed @ KU

Leuven) machined by

Case study – gears for planetary box

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• Zr02-TiN machined by Wire-EDM fail at 115 Nm static load ↔Y-Zr02 (injection molded) fails at 90 Nm

• After applying maximum load (8000 rpm input, 30 Nm output load, 40 rpm output) for 160h, no wear on ceramic gears

• In the experiment, gear box failed after 1450h under maximum load by a broken tooth

• High wear on planetary gear made of hardened steel (16MnCr5)

Results (loading)

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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Manufacturing of micro gears

108Research Group “Advanced Manufacturing Processes”

Department of Mechanical Engineering

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• Injection moulding• EDM

• Example – micro gear made of ZrO2-TiN 60/40 • Ø1 mm gear machined by Micro-EDM

Similar technologies

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

Material E [GPa] Hv [kg/mm2] KIC, 10kg [MPam0.5] K [W/m°K] ρ [10-5Ωm]

Zr02-TiN 280 1350 9.7 6.41 2.94

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• (Micro) milling EDM• “Milling”- like process• 0.5 mm standard tube as tool

which can be wedged to smaller diameters

Micro EDM of micro gears

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

tool

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• Micro Gear mold• Depth: 0.9 mm• Tool:

• Ø 0,5 wedged to 0,26 mm for pocketing• Ø 0,5 wedged to 0,113 mm for contouring

• Machining time• 38 min. of erosion | 44 min. of wedging

Applications

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

200 µm

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• Bouquet J., Hensgen L., Klink A., Jacobs T., Klocke F., Lauwers B., Fast production of gear prototypes – a comparison of technologies, 6th

CIRP international conference on high performance cutting, HPC 2014

• Bouquet J., Van Camp D., Vanhove H., Clijsters S., Amirahmad M., Lauwers B., Combining machining and hardening in one setup, applied on C45-steel, 8th International conference on photonic technologies, LANE 2014

• Malek O., Vleugels J., Perez Y., De Baets P., Liu J., Van Den Berghe S., Lauwers B., Electrical discharge machining of ZrO2 toughened WC composites, Proceedings of the 17th Plansee Seminar on High Performance Materials, Reutte, 2009

References

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering

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• VLAIO for various research projects, in cooperation with Sirris and FlandersMake

• Machine Tools Technologies Research Foundation (MTTRF) for providing the machining centre “Mori Seiki NTX2000” to KU Leuven to be used in various research and educational programs

• GF Agie Charmilles for providing various EDM equipment

• Siemens for providing CAD/CAM & NC-programming softwre

Acknowledgement

Research Group “Advanced Manufacturing Processes”Department of Mechanical Engineering