Influence of Shear Cutting Process Parameters on the Residual Stress State and the Fatigue Strength of Gears

Daniel Müller, Jens Stahl, Isabella Pätzold, Roland Golle, Thomas Tobie, Wolfram Volk, Karsten Stahl

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

1 Scopus citations

Abstract

Shear cutting is used for manufacturing various parts ranging from, e.g. simple washers to complex gears. The latter are typically subjected to cyclic loading and fail foremost due to fatigue damages. Hereby, the part’s lifetime is mainly determined by the geometry, the applied load, the material, the hardness, the roughness, and the residual stress state. While numerous research works deal with the influence of the process parameters on the hardness and the part’s geometry, the influence of the process parameters on the residual stress state and on the resulting fatigue strength has not been investigated in detail, yet. In an earlier publication, suitable shear cutting techniques, which allow achieving a high amount of clean cut and a favorable residual stress state were compared. In this paper, the influence of the process parameters on the residual stress state and the resulting bending fatigue strength are addressed. To simulate the bending stress occurring in the tooth root, C-shaped specimens were manufactured by different blanking techniques. The die clearance and punch and die edge radii were varied with these blanking techniques. After measuring the cut-surface geometry, the hardness distribution, and the surface roughness, the fatigue strength was determined in a pulsating test rig. By carrying out residual stress measurements using X-ray diffraction and simulating the material flow behavior using the Finite-Element Method, basic mechanisms, which are influencing the residual stress state and the resulting bending fatigue strength, were identified and will be presented and discussed in the paper.

Original languageEnglish
Title of host publicationForming the Future - Proceedings of the 13th International Conference on the Technology of Plasticity
EditorsGlenn Daehn, Jian Cao, Brad Kinsey, Erman Tekkaya, Anupam Vivek, Yoshinori Yoshida
PublisherSpringer Science and Business Media Deutschland GmbH
Pages2331-2344
Number of pages14
ISBN (Print)9783030753801
DOIs
StatePublished - 2021
Event13th International Conference on the Technology of Plasticity, ICTP 2021 - Virtual, Online
Duration: 25 Jul 202130 Jul 2021

Publication series

NameMinerals, Metals and Materials Series
ISSN (Print)2367-1181
ISSN (Electronic)2367-1696

Conference

Conference13th International Conference on the Technology of Plasticity, ICTP 2021
CityVirtual, Online
Period25/07/2130/07/21

Keywords

  • Fatigue
  • Fineblanking
  • Gears
  • Near-net-shape blanking
  • Residual stresses
  • Shear cutting

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