Ultra-short, forming-based process chain for powertrain components

Objective

• Developing new, forming-based process chains for hollow gear shafts
• Designing more resource-efficient partial processes; improving final component properties
• Exploiting lightweight construction potential (from the solid shaft to the hollow shaft, i.e. more compact gear units) 

Approach

• Substitution of machining processes by more resource-efficient forming processes
• Introduction of effects from forming technology into the gear components

Development objectives

Spin extrusion:

• Raw material: 40% reduction
• Component mass: 30% reduction
• Processing costs: 10% reduction

Gear rolling:

• Raw material: 30% reduction
• Process time: 50% reduction
• Load-bearing capacities: 20% increase

Benefit

• Reduction of process times and material usage
• Improvement of final component properties (strength, wear, surface topography)
• Shortening of complete process chains
• More economic production of gear components