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

Purpose and goal

In this project, a test method will be established where process optimizations in gear manufacturing can be tested in a more simple and efficient approach with lower waste, higher flexibility and faster testing times. The developed method will be used to investigate the performance of high-speed steel tools without cobalt with the aim to reduce the need of cobalt in the automotive industry due to its connection to human right risks. Furthermore, the methodology is aimed to allow companies throughout the entire value chain to test new products without the need of gear machining machines.

Expected effects and result

The project is expected to deliver: - An efficient test method for evaluating gear machining parameters. - Benchmark of tool performance for various HSS tool materials in gear machining to find tool variants without cobalt that can machine high-quality gears for a more sustainable production. - Recommendations on tool material and tool coating combinations for different gear materials for a more productive gear manufacturing. - Guidelines connected to the developed test methodology and gear machining strategies - Increased knowledge of modern gear manufacturing processes.

Planned approach and implementation

The project will be executed in six work packages where a test method will be developed by utilizing the expertise of the project consortia and by performing industrial trials. The developed methodology will then be used to evaluate the performance of high-speed steels with different cobalt content.The project consists of the following work packages: 1 - Decision on process parameters, 2 - Test method development, 3 - Validation trials: hobbing, 4 - Validation trials: power skiving, 5 - Simplified gear cutting, 6 - Project management and dissemination.