Development of a high-performance turning and gear shaping process for the production of internally toothed components from ausferritic cast iron with spheroidal graphite

The demanding machinability of ADI materials has hitherto made it difficult to use these materials economically in toothed components. The aim of the project "Development of adapted machining strategies for the production of toothed components from ADI" is the analysis, evaluation and development of turning and impact processes for the production of large modulus toothed components from ADI. A focus will be placed on the machining of turning groups and turning finishes, both of which are particularly critical due to spontaneous and unpredictable tool breakage. The machining of the casting skin, which is unavoidable with cast components, is also investigated. Another focus is on gear shaping, which is characterized by small chip cross-sections and multi-flank chips. The project focuses on a holistic approach to the machining of ADI hollow gears.

The technological and economic potential of the substitution of steel gears by those from ADI has already been exemplarily proven (reduction of manufacturing costs of up to 40 % possible), but is far from being exhausted due to the lack of knowledge about demanding machining. In addition to the usual transfer measures such as status reports, progress reports, publications, further training of students, etc., the research results achieved are already being applied and validated in companies of the project committee during the project period. The market for large-modulus, interlocked components is characterised by small quantities. The casting process, the heat treatment characteristic of the material and the machining of these components are predominantly carried out by small and medium-sized enterprises (SMEs), for whom the results achieved in the project secure significant market advantages.