Research Topic
| Short Title | Laserhärtung Verzahnung |
| Start of Project | Q4/2023 |
| Funding | FVA-Nr. 1004/I, IGF-Nr. 23042 BG/1 Federal Ministry for Economic Affairs and Climate Action, BMWK |
| Project Partner | Fraunhofer Institute for Material and Beam Technology IWS |
| Contact | Dr.-Ing. T. Tobie |
Project Description
Today, case-hardening is widely used and established for small and large gears. However, disadvantages include batch processing, energy consumption, and processing time. Induction hardening is an alternative with shorter processing times for small gears with high batch sizes, but it is associated with high tool costs and efforts to determine process parameters. Load-carrying capacity values are somewhat lower than those in case hardening (FVA660 I/II).
The laser hardening of gears is considered a suitable alternative for small production runs (e.g., prototypes, small series). Key advantages include short processing times, low energy consumption, processing a wide range of components without tool changes, no pre-series required for heat treatment adjustment, precise adjustability of temperature distribution through parameter adjustments, compensating edge effects through beam shaping, possible elimination of additional tempering heat treatment, and flexible beam shaping with zoom and scanner optics for reproducible quality.
The widespread use of the laser-hardening of gears is currently limited, particularly due to insufficient knowledge about suitable process parameters, achievable hardness properties, and load-carrying capacity values. The planned investigations aim to address these gaps and enable the application of laser-hardening as a beneficial alternative to heat treatment for suitable gears.
In an analysis of various equipment techniques, a suitable system for investigating the laser-hardening of gears must first be defined. Strategies for beam focusing and movement need to be developed and evaluated. Achievable hardness patterns and hardness profiles in profile height and width, as well as depth, depending on the process parameters, will be examined. If overlaps cannot be avoided, the effects on the microstructure and hardness profiles must be analyzed, followed by determining the impact on load-carrying capacity. Based on this, a suitable process strategy with the corresponding process parameters needs to be identified and optimized. The defined process is to be implemented on gears of different geometries and sizes to determine load-carrying capacity values for the tooth flank and tooth base. The results should indicate process limits and provide recommendations for industrial application.