Eventos Anais de eventos
COBEF 2023
12th Brazilian Congress on Manufacturing Engineering
Study of the effect of the Isotropic Superfinishing on the surface integrity of gears
Submission Author:
Gilberto Gomes , SP
Co-Authors:
Gilberto Gomes, Tiago Colombo, Angelo Carvalho, Ronnie Rego, Angelo Lanza, Antonio Gallinucci
Presenter: Gilberto Gomes
doi://10.26678/ABCM.COBEF2023.COF23-0287
Abstract
In recent years, the term "electric mobility" has been the focus of several discussions and studies. The electrification of mobility is seen as a way to minimize greenhouse gas emissions since transportation based on an internal combustion engine is responsible for about 15% of the global carbon dioxide emission. Electric mobility is accompanied by tighter surface quality requirements of the transmission gears. Therefore, improvements in surface finishing processes are necessary. Due to the micrometric scale surface correction and the homogeneous distribution of surface loads, the Isotropic Superfinishing process, in which its functionality is linked to chemical embrittlement and later an abrasion process, has been taken as a possible application in electromobility gears. Thus, this study's main objective is to evaluate Isotropic Superfinishing's impact on the surface integrity of gears. It is presented a method to assess different conditions of Isotropic Superfinishing in carburized & hardened DIN 20MnCr5 gears, including processing time and abrasive material. For characterization, experiments of geometric evaluations, topography, residual stress, and durability tests were developed. Results showed a significant decrease in surface roughness in both abrasives investigated. On the other hand, one of them observed a higher profile bulging tendency. For the durability tests, simplified samples processed via Isotropic Superfinishing were tested in the rolling contact fatigue (RCF) test rig. They showed a fatigue lifetime of approximately five times higher than the ground samples. Thus, due to the roughness reduction, the Isotropic Superfinishing process applied to gears can offer a higher fatigue life compared to conventional finishing processes. However, the process and its procedural variables must be fully understood not to impair the expected gear profile and thus increase load capacity, fatigue life, and gear efficiency.
Keywords
Isotropic Superfinishing, surface integrity, gears
