RPIMastersEngineeringProject_HQuinn.ppt.pptVIP

RPI Masters Engineering ProjectAnalysis of Near Net Shape Forged Gears for Helicopter Transmissions Holly Ann Quinn September 28, 2010 Problem Statement Is using Near Net Shape (NNS) Forging a better way to manufacture gears for helicopter transmissions? Potential Benefits Lower Cost Minimal Waste of Raw Material Streamlined Process Decreased Manufacturing Time Equal Strength, Hardness and Fatigue Properties Potential Detractions Higher cost of manufacturing tools, i.e. Forging Dies May need to replace dies more frequently and at greater cost than cutting/grinding wheels Unknowns Can Hardness and Fatigue properties of gears manufactured with NNS forging match those of “traditionally” manufactured gears? “Traditional” Method of Gear Manufacturing Cutting/Rough Machining Operations Gear teeth can be generated in multiple ways, such as hobbing or a cutter (horizontal or vertical): Material Processing Carburization is a process performed at high temperatures during which carbon gas is infused into the coast and drive side of gear teeth to achieve adequate hardness levels. Tempers are performed to toughen the material and increase ductility. Heat Treatment often via Quenching is performed to harden the material by rearranging the microstructure to martensite. Finish Machining and Grinding Gear Teeth are ground to achieve accurate geometry, as well as remove any distorted material acquired during heat treat. Bearing Journals, Diameters are machined to Blueprint dimensions. Final Material Processing and Plating Low Temperature Heat Treatment/Stress Relief Bake Cadmium or Silver Plating to increase strength. Shot Peening to increase strength. Gear Manufacturing with Near Net Shape Forging Method of Manufacturing with NNS Forging The process begins with a billet or piece of forged material stock which is heated to some temperature and flattened into a “pancake” by a press. Then, the stock is usually “punched” with a die into a mold so that the stock takes the