EcoGear - Environmental Friendly Bevel Gear Production by Using Pre-Forged Blanks

Purpose and goal

The purpose of the project was to demonstrate the possibility of using preforged gear blanks with tooth gaps in production of crown wheels. This saves material and reduces processing cost for increased environmental sustainability and competitiveness. The project has shown that 9% savings in material compared to conventional methods is possible, but also demonstrated that savings of up to 20% are possible. The project also shows that the final component is of the same quality as when produced with a conventional process.

Expected results and effects

Savings in material transportation and reduced processing costs for the production of bevel gears are the project´s main results. The high noise level that arose during intermittent turning is seen as an obstacle to switch to the new process chain. Further studies on changes of tools and the effect on machine tools are recommended before full transition to pre-forged blanks. If the new process method is applied, an outcome is expected where the material after forging is up to 20% lighter, which leads to higher environmental sustainability and production efficiency.

Planned approach and implementation

The project has carried out tests in a laboratory and industrial environment. The tests in a laboratory environment have, among other things, studied the material and tool wear in order to acquire knowledge and propose process parameters for industrial verification. Both researchers and industrial actors have collaborated to solve challenges and arrive to an industrially viable process. The project has had challenges with change of people who participated in the project, especially the closing down of the research center that coordinated the project.