Forging of multi-metal gears

Abstract

Material substitution is becoming increasingly popular in the transport sector, since the reduction of emissions is closely linked to the reduction of vehicular weight. In the case of gears, the aim is to reduce the gearbox assembly weight with the manufacturing of light-weight gears made of multiple metals, instead of conventional ones made of steel. In this thesis, different material combinations are tested to produce a 13-teeth spur gear with forging. The intermetallic bond between the dissimilar metals is also observed, to determine the gear’s performance. From the experimental results, it was noted that there was no sufficient deformation of the gears due to the inadequate capacity of the hydraulic press. In addition, the forging conditions were not beneficial for a successful bond between the dissimilar metals, in most cases. Only two gear samples were found to be bonded, however in one case there was a visible gap between the different metals, while in the other one, when observed under an optical microscope clear boundaries of the materials signified that the experimental conditions were not favorable for diffusion.