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Hardness prediction after case hardening and tempering gears as first step for a local load carrying capacity concept

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Abstract

In recent years the problem of case hardened gear failure due to crack initiation below the surface and its prediction has been addressed thoroughly. However, the main factor in terms of load-carrying capacity, namely the hardness and residual stresses are either considered rudimentarily by analytical functions or within very complex finite element codes.

Commercially available software such as the FVA Workbench is limited to standard calculations according to the DIN 3990 or ISO 6336 and mainly focuses on the loading aspect. Heat treatment tools such as HT-Tools, CarbTool© or SimCarb mainly focus on the carburizing process without modelling the quenching process for the hardness predictions.

The model being presented within this paper focuses on calculating the hardness depth profile for spur (straight/helical) or bevel gears considering all physical aspects of the carburizing and quenching process. The thermodynamically-based diffusion and phase transformation models allow heat specific chemical compositions to be considered. The hardness reduction due to tempering has been derived from quality assurance data in order to level out varying tempering temperatures used during production. Considering gear specific aspects in both the carburizing and quenching simulation allow very good predictions which have been validated up to module 10 mm.

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Acknowledgements

The authors gratefully acknowledge Jannick Kuhn for his fundamental contribution during his B.Sc. thesis by implementing the phase transformation model and the quality assurance team for providing hardness measurements for validation purposes.

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Authors and Affiliations

  1. SEW-EURODRIVE GmbH & Co. KG, Bruchsal, Germany

    Maximilian Schwenk, Jürgen Hoffmeister & Jörg Hermes

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  1. Maximilian Schwenk
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  2. Jürgen Hoffmeister
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  3. Jörg Hermes
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Correspondence to Maximilian Schwenk.

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Schwenk, M., Hoffmeister, J. & Hermes, J. Hardness prediction after case hardening and tempering gears as first step for a local load carrying capacity concept. Forsch Ingenieurwes 81, 233–243 (2017). https://doi.org/10.1007/s10010-017-0247-8

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  • DOI: https://doi.org/10.1007/s10010-017-0247-8

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