Académique Documents
Professionnel Documents
Culture Documents
Howard I. Sanderow
Raw
l'I('III('lIlalo,'
MateriaJs
\lIm
"d.lt IIIlId,'",
\ddiliH"
11'l'.lphile. HIl' I uhrk.IIII"
owder
metallurgy
i a precision
(PIM)
or ~ear-net
shape. an~ it
__
Forming
I
11.. 1 ( 1I11111.1I'1illl1
(,,,lei ( umpartion
Isostatic
Extrusion
Die Compacting
Spraying
Pressureless Sintering
Die Compacting
Iso tatic
Rolling
Injection Molding
Slip Casting
Sillh'ril1~
parts: mixing,
Atmosphere
Vacuum
High Temperature
compacting
and
to pro-
sintering,
pressing/double
sintering
and
powder
Altemati vely,
a geometric
feature
compaction.
Powder metal
not possible
or to achieve
parts
or surface-hardened
hardened
prop-
tep may be
macmning
intended
Slntering
in
schematically
may be
through-
as required
by the
application,
and lower
are
punches
used
to com-
OptJorud
Operauons
drawn.
. 1
the pressed
lower punch,
"1,'P'
ejected
by the
the part
Repressing
Coining
Sizing
Resintering
Forging
Rerolling
Metal Infiltration
forward
and refills
the die
lugs,
splines
incorporated
Optional
1 im'hin~
is
compact
Lightening
"'1"1"
such
and cam
during
holes
features
the
as keyways,
contours
may
compaction
may be added
be
process.
to reduce
part
Machining
Heal Treating
Steam Treating
Plastic Impregnation
Plating
Tumbling
Oil Impregnation
Shot Peening
ners, eliminating
the undercut
good
form accuracy,
accuracy
runs. Generally,
surface
finish
because of
con-
and surface
finish
over
their
and constant
tool
Finished Products
!'wellll'l
GEAR
TECHNOlOGY
of applications.
for appliances,
34
for a number
applications.
includ-
tractor transmisanda
number
of
mechanical
porosity
properties
in the
same-size
(due
of
may limit
the
microstructure)
replacement
of wrought
Higher
temperature
by
of the applied
helical
gears. Insufficient
powder
is u ed
the corresponding
A portion
effects
motion
Frequently
mechanical
properties)
in
for both
with greater
decreases.
face widths
Dimensional.
during sintering
0
distortion,
having
variations
relationship',
larger
gear design
data requirements
Committee
on the development
of a new
Gear Speeifications,"
This
agreement,
during
either as specific
Mechanical
Design
the next
mechanical
PIM
Criteria
step
requirements
gear
features of a
the e
and a potential
overload
condition.
load
Two types of
failure.
reviewing
methods
of
is
Committee
evaluating
the
vide a impleequation
capacity
for determining
once certain
mechanical
steel materials
the load
and bevel)
of the P/M
properties
anequa-
density
Where
d ::::calculation
tandard,
"Powder
is expected
specification
are quite
to include
Pd
K2
= constant
strength
pilch (inl)
diametral
when
(in)
diameter
data.
derermining
design stage:
desermining
overloading
condition.
2. Providing
althe
note if functionally
3. Consideration
ty.
S, has
under a sudden.
been determined
and
the
critical.
culated.This
modate adherent
gear
so small bum; do
capacity
I. Denoting
also be considered
nOI.interfere
items
Powder Metallurgy
years.
of these
especially
Metallurgy
during
after processing.
design discussion.
correctly.
PIM
consideration
mechanical
Th:is is a reciprocal
mark: on
in tool orientation
is specified
cop-
materi-
ity planning
'(0
for missing
preliminary
causes
density
compaction
determined,
fin~shmg operation.
an allowance
6 .. An allowance
metal
al (if possible).
in the
defects,
of raised
of P1M gears.
may be overcome
5. Including
Proper
or case hardening
the perfonnance
stress limitations
a vibratory
born
or warm com-
inter process
paction
Bending
to the presence
4. An allowance
gear geometry
T. can be calto (he actual
if T is
then an acceptable
material
for
Howard I..
Sande.row
is the presiden of
Management &
Engineering Technologies,
Day/on, OH. He has
written a number of
article and presemed
seminars on powder
metal subjects.
SEPTEMBER/OCTOBER
lV~e
35
'fable 2
I' '\ I
r..
\1.,,"01,1\
Gear Size
Pitch Diameter
Max
Runout
!DID
IJ.Il1
r.
Tole
Typical Manufac:turln
"r ()""Ii(\
till.
PI
lit
, ......
Tooth-to- Tooth
Total Composite
AGMA
Error
Error
Class
j.lffi
IJ.Il1
(Approx.)
Secondary
Operation
,----16
35
40
75
None
25
30
55
20
20
40
8
9
Bore
Size
40
100'
45
40
85
None
35
25
60
25
20
45
8
9
Bore
I
--
55
130
60
40
100
Size
40
100
Bore
--
75,
45
I
I:
Size
None
3&
GEARTECHtoiOLOGY
Mechanical testing of a stafistically representative sample from each production lot is used to
demonstrate the mechanical quality of the product. Test methods include tooth torque tests or
tooth breaking strength tests {either static or
impact load:ing).
Advances 1:0Further Improve P/M Gears
Efforts are already underway at specific PIM
gear manufacturers, as well as at powder producers and process equipmeru suppliers, 10 improve
both the dimensional control and the mechanical
properties 0'( .PiM gears.
Dimensional Control. The dimensional CODistency of gears can be improved either in the
sintered condition or throughthe heat treatment
process. One method, which is said to create
AGMA '09' gears from a Q6 gear, (Refs. 7-8) is
the surface rolling of a sintered .P(M gear
against a master gear, Sinter-hardening .P/M
gears can reduce the distortiouassociated
with
more conventional quench and temper heat
treatment processes.
TO'othDensity Inerease. Four primary methods
to increase PIM gear tooth density are under study.
I. Roll Densification. This effective dimensional control method also densifies the gear
tooth surface. Improvement in bending fatigue
strength of 32% and a 3.5 times increase in contact fatigue stress has been reported for casehardened 4600-type PIM steel gears subjected to.
this process (Takeya at al.). Contact fatigue
strength 01'96% of that of case-hardened wrought
AISI 4] ] 8 steel has also been reported.
2. Warm Compaction. This process is much
the same as conventional powder metal part compaction, except that both the meta] powder and
the looting are heated to approximately 300,oF
before processing.
In preliminary tests, gears
manufactured using warm compaction showed an
increase of 30% in tooth break load. When the
process was coupled with. high-temperature sintering.jhe improvement was over 5'0% (Ref. 9).
3. Rotopressing. The Rotopressing precess,
which subjects parts to large tangential stresses,
causing intense. local plastic flow and densification, has been reported to give densities greater
than'" .6g1cm3 in sintered PIM gear teeth,leading
to excellent fatigue and wear properties (Ref. 1'0).
4. Ausrolling, This process combines surface
densiflcation and heat treatment (Ref. ] 1).
Ausrolling of aconventional PIM steel is reported to have reduced the surface porosity fr~m ]4%
to less than 2%, increased the (oUillg contact
fatigue endurance by more than 10 times and led
to substantial improvements in gear accuracy and
surface fini b (Ref. 12).
Conclusions
The powder metallurgy process can provide
gear designers with a cost-effective alternative to
machined, wrought steel gears. This net. shape
process offers dimensional tolerances and
mechanical properties compatible with. many
market applications. As current process improvements and material developments are incorporated, more high performance transmission gears
win be converted to. powder metallurgy. 0
References
1. Powder Metallurgy Design Solutions. Metal Powder
Industries Federation, Princeton, NJ, 1.993.
2, Powder Metallurgy Design Manual, Second Edition,
Metal Powder Industries Federation, Princeton, NJ, 1995.
3, Prucher, T. and U. L Sanderow .."Surface Fatigu.e of PIM.
Alloys," Ad~ances in Powder Metallurgy & Panlculat
Malerials-1994,
Vol. 2, Melal Powder Industries
Federation.
4. Smith, W. E. "Ferrous-BasedPowder Metallurgy Gears,"
Metals &ginuri/lg
Quarterly. November, 1974.
5. Lin., Soy et al. "A Comparison of Tensile, Rot;lling
Bending Fatigue, and Axial Fatigue Tesl Results of PIM
Alloys." Advances in Powder Metallurgy &: Particulate
Materi'als-1994,
Vol. 7, Metal Powder Industries
Federation.
6. Hirata, H. et al. "Loading Bearing CapacilY of Ferrous
Sintered
Gears." Proceedings
of the 1993 Powder
Me.tallurgy World Congress. Kyoto, July 12-15, 1'993,
Japan Powder Metallurgy Association.
7, Takeya, Y. et at. "Surface Rolling of Sintered Gears,"
SAE Technical Paper 820234, Society of Automotive
Engineers. 1982.
8. Cofer, 1. and P. Wintenon."High
Performance PIM
Gearing.rPresented at SAE Congress, Detroit, MI, March
1993,
9. Chmelar, j et al. "Evaluation of 'the Ancordense Single
Compaction Proeess and HPP Processing 'Iechniques in
Fine Pitched Spur and Helical Gears," Advances in Powder
Melallurgy and' Particulate Matl!nals-./994,
Vol..S, Metal
Powder Industries Federation,
10. Miskiewlcz,
L. "Ultra
High Metal PQwder
Densification
for Manufacturing
Highly Loaded
Automotive Parts ... SAE Technical Paper 940387, Society
of Automotive Engineers, 1994,
U, Kuplen, S.T, et al. "AusroUing Sintered Steels for
Bearing Elements." Advances .in Powder MeJaUurgy &
Particulate Marerials-1992,
Vol. 2, Metal Powder
Industries Federation,
12, Senti, - , er al. "Ausform Finishing of Gears."
Industrial Healing. April 1995,
Acknowledgemel1t5: Longer versions ofthis material were
presented at the 1995 A.GMA. Fall Technical Meeting q!ldat
the .1996 SME.1 st lmemational Advanced Gear Pl'Oussif!g
&: Manufacturing' Conference, They are available from
AGMA as 9SFrM J 3 and from SME as "Powder Mell:lllurgy
Gears-Expanding
Opportunities" by James &: Sanderow.
SEPTEII.!BEFlIOCTOBEFI
11g8
31