During the design of electric vehicles, significant efforts are being made to identify and implement lightweight construction potentials to enhance efficiency. The electric motor is a major weight driver due to its large dimensions, necessary to meet the high torque demands at low speeds. To address this drawback, new drive concepts are being developed that utilize smaller electric motors operating at high speeds with reduced torque. These concepts require the synchronization of the motor's high speeds with the drivetrain through a reduction gearbox. The high centrifugal forces of high-speed drivetrains impose additional stresses on the gears, resulting in the need for increased material strength. A well-established process in gearbox manufacturing is fixture hardening, where gears are fixed by mandrels during quenching to minimize component distortion. This paper presents a novel fixture hardening procedure where the forces applied by the fixtures are precisely controlled. By applying targeted forces during the martensitic transformation, the load carrying capacity of the material can be significantly improved. Pulsator tests on tooth root load carrying capacity for two different materials demonstrate the potential of this process for case-hardened gears. It is shown that the developed fixture hardening process offers a simple and easily integrable solution for enhancing the load carrying capacity of gearbox components in existing production lines.

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Influence of a Novel Fixture Hardening Procedure on the Tooth Root Load Carrying Capacity of Case-Hardened Gears

  • Yves Johannes Barth,
  • Sven Wagner,
  • Martin Hunkel,
  • Thomas Tobie,
  • Karsten Stahl

摘要

During the design of electric vehicles, significant efforts are being made to identify and implement lightweight construction potentials to enhance efficiency. The electric motor is a major weight driver due to its large dimensions, necessary to meet the high torque demands at low speeds. To address this drawback, new drive concepts are being developed that utilize smaller electric motors operating at high speeds with reduced torque. These concepts require the synchronization of the motor's high speeds with the drivetrain through a reduction gearbox. The high centrifugal forces of high-speed drivetrains impose additional stresses on the gears, resulting in the need for increased material strength. A well-established process in gearbox manufacturing is fixture hardening, where gears are fixed by mandrels during quenching to minimize component distortion. This paper presents a novel fixture hardening procedure where the forces applied by the fixtures are precisely controlled. By applying targeted forces during the martensitic transformation, the load carrying capacity of the material can be significantly improved. Pulsator tests on tooth root load carrying capacity for two different materials demonstrate the potential of this process for case-hardened gears. It is shown that the developed fixture hardening process offers a simple and easily integrable solution for enhancing the load carrying capacity of gearbox components in existing production lines.