Development of adapted cutting strategies for the production of toothed components from ADI

 

Starting Situation

Cast components made of ADI combine strength or elongation at break for steels commonly used in drive technology with the design freedom of casting technology. The advantages of this material predestine the use of ADI especially for hollow wheels with larger component dimensions (m > 8 mm). The economical use of this potential-laden material is often prevented by its demanding machinability. The machining allowance required by casting technology means a high material volume to be machined for turning. In gear manufacturing, a complex meshing kinematics is superimposed on the demanding machinability.

Research Objective

The aim of the research project is the development of adapted machining strategies for the economical production of toothed components of different dimensions from heat-treated cast iron with spheroidal graphite (ADI). The most widely used ADI 900 is being investigated as a material. The demanding machining of ADI, which differs significantly from both the machinability of conventional cast iron and that of steel materials, represents an economic hurdle for the use of ADI materials. The machining processes investigated should be the turning and manufacturing of the gear teeth, as these represent the key operations from the user's point of view. With regard to gear production, the first step is limited to gear hobbing for the production of internal gears.