Innovative powder based manufacturing of gear wheels with high performance (HIPGEAR)

Important results from the project

The aim of HIPGEAR is to develop a new material and processing technology for manufacturing of high performance gear wheels for heavy vehicles. The technology is based on powder metallurgy with the processing steps pressing sintering and HIP ing. The new technology has advantages from environmental and cost point of view through reduction of material waste with up to 50%. The technology can also give improvements in production flexibility, quality and performance of final products. Digital tools were also developed for process planning of the new manufacturing chain.

Expected long term effects

A new technology was developed for powder metallurgical manufacturing of gear wheels with full density. The new technology has cost advantages compared to previous attempts to generate powder metallurgical gear wheels with full density. With the new technology it is possible to manufacture gear wheels with smaller impact on environment and with better performance. This can contribute to a future solution of smaller, lighter gear boxes ready for higher engine outputs. There are positive effects on competitiveness, energy, quality and flexibility from the new technology.

Approach and implementation

The technology was developed by material and process optimisation on three types of test objects with different level of complexity: Test cylinders, small and large gear wheels up to 8.4cm diameter. Possibilities and limitations of the new technology was analysed with digital models which describe the full process chain. Finally demonstrators were tested with respect to fatigue. The project resulted in Guidelines for suitable material and process routes which produce gear wheels which are competitive with wheels from conventional production.