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4. October 2018

Lightweight design: thermomechanical precision forging

IFUM | IFUM uses thermomechanical process control to produce thin-walled gear rims. Within the scope of the joint research project “Lightweight Forging”, such gear rims are combined to weight- and efficiency-optimized gear wheels used for gearboxes in cars.

The central demonstrator developed in the joint research project "Lightweight Forging" is a gear wheel in multi-component design with optimized weight and efficiency. IFUM’s contribution is a thin-walled gear rim produced using multi-stage precision forging with thermomechanical process control. Thanks to a second forming stage at reduced temperature, the grain size of the case-hardened steel used can be reduced significantly. In addition, the second forming stage serves for component calibration in order to improve component accuracy and surface characteristics.
Research results prove that a fine-grained structure increases the strength and resistance of forged parts, thus making components more robust and less prone to failure. This and the multi-component design make hybrid gear wheels a lot lighter than previous versions. Consequently, vehicles have a lighter weight and an improved energy efficiency. Moreover, the production process is more resource-efficient, because less postprocessing is needed due to an improved contour accuracy and average roughness value.

by Julian Diefenbach

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Benefits derived from research results

  • Multi-stage precision forging at different temperatures
  • Process-integrated thermomechanical treatment in single-part production
  • Optimized grain sizes by means of thermomechanical process control
  • Improved geometry and surface through second forming process
IFUM_Praezisionsschmieden_Bild1_01
Lightweight design: IFUM produces thin-walled gear rim using thermomechanical process. (Source: IFUM)
IFUM_Praezisionsschmieden_Bild2_01
IFUM forges a gear rim which is joined to a multi-component gear wheel in further subprojects. (Source: IFUM)
IFUM_Praezisionsschmieden_Bild3_en
In the first stage, the preform is forged and in the second stage, the toothed ring is expanded, thus forming the tooth roots. (Source: IFUM)
IFUM_Praezisionsschmieden_Bild4_en
Thermomechanical precision forging produces fine-grained structures with improved robustness and strength. (Source: IFUM)
IFUM_Praezisionsschmieden_Bild5_en
The evaluation of the geometric properties shows an improved contour accuracy. (Source: IFUM)

Contact

Dipl.-Ing. Julian Diefenbach

(0511) 762-2428
diefenbach@ifum.uni-hannover.de
www.ifum.uni-hannover.de

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Similar posts

  • Exact temperature measurement during hot stamping
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