Simplified Test-method for Cobalt-free Machining of Gears (SiTCoM)

Important results from the project

The initially set goals have been reached. A test method has been developed and used that clarifies the impact of different factors on the tool wear in the gear manufacturing processes skiving and hobbing. Our tests show that the Co free variants can replace the standard 8% Co materials used today in several cases. The results have been confirmed in industrial tests. Several test setups have been developed within the project that may be very useful in future work.

Expected long term effects

The test method is a quick way to assess tool wear in gear manufacturing processes. In combination with detailed studies of the industrial trials it can give increased understanding of the specific demands put on the gear tools. This may in future lead to the development of specific tool material solutions for skiving and hobbing with a reduced use of Co. Already today several grades exist that can perform well at the relatively low cutting speeds used in many gear manufacturing processes.

Approach and implementation

All work packages from the project plan were executed but not necessarily in the planned order. We encountered several problems: Getting new materials through the tool production lines was a challenge. Manufacturing unique HSS inserts proved difficult and costly. The chosen work material gave slower wear rates than expected. Access to factory machines was limited and the demonstrator production was cancelled. All these problems were solved by an excellent committee.