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Gear Hobbing Predictive Model
Navy SBIR FY2010.2
| Sol No.: |
Navy SBIR FY2010.2 |
| Topic No.: |
N102-122 |
| Topic Title: |
Gear Hobbing Predictive Model |
| Proposal No.: |
N102-122-0783 |
| Firm: |
Third Wave Systems, Inc.
7900 West 78th St.
Suite 300
Minneapolis, Minnesota 55439 |
| Contact: |
Troy Marusich |
| Phone: |
(952) 832-5515 |
| Web Site: |
www.thirdwavesys.com |
| Abstract: |
This program will demonstrate the feasibility of innovative physics-based modeling of gear hobbing to predict and improve residual stresses and heat treat distortions while reducing production cycle times and costs of transmission gears. TWS will develop a general, validated, physics-based modeling capability for the gear hobbing process, resulting in detailed chip formation and residual stress prediction. This will be achieved through both a detailed finite element modeling of tool-workpiece interaction, and CNC toolpath-level analysis. The combined outputs of these comprehensive models will provide the ability to predict machining-induced residual stresses and their effects on distortion from subsequent heat treatment, and determine interactions between machining process changes and cost, cycle time and workpiece characteristics.
Feasibility will be demonstrated by: 1) advancing physics-based machining modeling for gear hobbing processes, 2) developing physics-based gear hobbing predictive models based on finite element modeling, and 3) validating these physics-based models against machining experiments. Anticipated results results of the program will: (1) predict residual stresses, forces, temperatures, and tooling performance for hobbing; (2) improve fatigue life of gear components through residual stress management while reducing cycle times and cost; and (3) advance knowledge of material removal mechanisms in gear hobbing and their effects on post-machining operations.
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| Benefits: |
Current processes for producing transmission gears involve hobbing or shaping a forged stock to obtain the gear shape. The amount of residual stresses, distortions, and excess material generated during hobbing and following heat treatment processes dictate overall cycle times and component performance. Therefore, it is necessary to understand and control the sources of process cycle times, costs, residual stresses, and distortion to minimize the production costs and improve transmission gear component performance. In contrast to expensive trial-and-error approaches currently used in practice, the proposed Phase I project will address machining issues through scientific analysis grounded in machining physics. Gear hobbing processes will be modeled off-line and in advance of process setup. This will allow new processes to achieve mature states faster, mature processes to be more productive, and improve part quality and reduce cost. In addition, engineers designing and manufacturing gears will be able to provide beneficial residual stress profiles to positively impact fatigue life and distortion. Tremendous opportunities exist for cost-reduction and performance improvement of transmission components by utilizing the proposed research in applications ranging from automotive and aircraft transmission systems, to energy production and heavy equipment manufacture.
In addition to direct commercial and societal benefits, this project will:
� Further increase the science and engineering knowledge base in both industry and academia regarding the fundamental relationships between materials, processes, and product quality of transmission components; and
� Remove significant cost barriers that exist when investigating truly innovative manufacturing methods and implementation thereof.
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