Manufacturing of hybrid

gears by incremental sheet-

bulk metal forming

Name: Anish H
Register Number:2021507305
Abstract
The weight of automotive components has to be reduced and additionally a higher
integration of functions is aspired. In the case of geared components, the
incremental sheet-bulk metal forming technology enables the manufacturing of
load- and weight-adapted functional parts. Due to locally adapted mechanical
properties by strain hardening, the subsequent conventional hardening and heat
treatment can be avoided for certain cases. However, with the application of high
strength steels, the strain hardening reduces the tool-lifetime of the filigree gear
forming tools. One possibility to increase the tool-lifetime and also the possible
gradient of the mechanical properties can be provided by the manufacturing of
hybrid gears. In this case, a stack of aluminum and steel sheets with different
initial diameters is joined by the combination of a consecutive edge-thickening
and gear forming process. This paper presents the experimental results. A
reduction of the tool-load by 20-30% compared to the monolithic process was
achieved. Furthermore the metallographic investigation proves the coexistence of
a form-fit and force-fit as the resulting joining-principle.
Introduction
One option to reduce fuel consumption of cars and aircrafts is the reduction of the moving
mass, which can be achieved by a substitution of parts with a load-adapted shape for
massive parts [1]. Demonstrative examples are components like seat-adjusters and starter
gears (fig. 1a) featuring functional elements like gears. These elements require a local
adjustment of mechanical properties due to the high loads in the later use. Especially in
the case of an accident the elements need a high ductility while during the common use a
high surface hardness is required to decrease wear. Conventionally, those parts are
manufactured by blanking where an adaption of the sheet thickness is not possible. In
contrast, planar parts with a load adapted shape can be manufactured by bulk forming
processes. In this case, the requirements on the capacity of the forming press rises
significantly. Thus, a large number of load-adapted parts are manufactured by metal
cutting processes. This increases the process-time compared to bulk-forming processes
while the material utilization decreases exceedingly. Furthermore, a subsequent heat
treatment is necessary to satisfy the mechanical requirements. This increases the
production costs and reduces the process efficiency. In the case of sheet-like parts, the
Sheet-Bulk Metal Forming (SBMF) technology offers a new opportunity to manufacture
load- adapted near net-shape components without any need for metal cutting processes
[2].
 Furthermore, the incremental Sheet-Bulk Metal Forming (ISBMF) offers a
significantly reduced tool load due to small forming zones compared to the dimensions
of the final part. This enables the manufacturing of load-adapted components on
presses with less capacity [3]. Manufacturing of functional elements by ISBMF
improves the mechanical properties due to a high plastic strain above φ = 2 and offers
continuous material fibers. In addition, the hardness distribution can be graded by a
variation of the process kinematic. This allows an adaption of the component properties
according to the later use of the component. Especially the strain hardening of high
strength steels decreases the tool-lifetime because of dimensional restrictions of the
forming tools due to the need of a chambering to control the material flow (fig. 1b). To
avoid the limitation in the grading of the hardness distribution due to a monolithic
structure and the challenge of high tool loads, the combination of different materials to
so-called hybrid components can be a solution. La Berge et al. [5] manufactured hybrid
gears by joining a dissimilar sheet to a previously milled bull gear. Politis et al. [6] and
Chavdar et al. [7] investigated bi- material gears manufactured by forging of a
telescoped cylinder made of copper and a ring made of steel into a geared cavity. This
material combination enables the manufacturing of gears with significantly graded
mechanical properties, while the load requirements of the machine are still high. The
possible joining principles for joining by forming and the requirements for a
metallurgical bond of dissimilar materials are presented in [8].
 In this paper, a new incremental Sheet-Bulk Metal Forming strategy for the
manufacturing of hybrid gears is presented and investigated focusing the
possible load reduction and the resulting joining principle.
conclusion
 Incremental Sheet-Bulk Metal Forming allows to manufacture sheet-like components
with a load-adapted shape. To increase the tool-lifetime or to qualify this technology
also for the manufacturing of high strength gears, the manufacturing of hybrid gears
was investigated. Hybrid gears can decrease the forming force by up to 30%
compared to a monolithic component, while the surface of the gear still consists of
the high strength material.
 To understand the existing joining principle, pull-out tests were performed. Here, the
joint strength after the thickening process increases significantly during the gearing
process. This effect is mainly achieved by an increased joining area. Whereas the
experimental pull-out force is just 1-5% of the calculated force for a metallic bond,
this type of bond seems not to be the dominant joining principle. Here, the resulting
contact stress, increase of the surface and temperature in the forming zone during
forming has to be investigated by numerical analysis and compared to the threshold
metallurgical Al-St joints.
My views on the research paper
This research aims to develop a new method for making hybrid gears for cars and
aircrafts. These gears are lighter and stronger than traditional gears, which can help
reduce fuel consumption and improve performance.
Problem:
 Need to reduce weight of car/aircraft parts to save fuel.
 Traditional methods for making gears are heavy, expensive, and require multiple
steps.
 High-strength steel is lighter but damages delicate shaping tools.
Blanking: cutting a shape from a sheet of metal, but not good for changing thickness.
Bulk forming: shaping metal by pressing it, but needs strong presses and can't make
complex shapes.
Sheet-Bulk Metal Forming (SBMF): a newer method that uses smaller presses and
can make complex shapes with varying thicknesses.
The problem with SBMF is that it can damage tools when using strong steel. So, the
researchers propose a new method:
Incremental Sheet-Bulk Metal Forming (ISBMF): shaping the gears and bonding
the layers at the same time.
The proposed solution:
 Hybrid gears: These are like layered sandwiches, using thin sheets of aluminum
(light) and steel (strong) bonded together.
 Special forming process: This (ISBMF) method shapes the gear and joins the
layers simultaneously, reducing weight and cost.
This new method should:
Reduce tool wear because the steel layer is thinner.
Make gears with varying strength in different parts.
Be cheaper and faster than traditional methods.
Making Hybrid Gears: Different Methods Explained
This section describes four different methods for creating hybrid gears using
incremental sheet-bulk metal forming (ISBMF). Each method has its own
advantages and disadvantages:
Method a-1 & a-2:
Uses a pre-thickened sheet and a solid ring with a cavity.
The sheet is formed into the cavity to create a form-fit joint.
Disadvantages:

 Wastes material inside the ring.

 Difficult to control material flow within the cavity.

Method b:
Uses a pre-thickened sheet and a small surrounding ring.
The ring can be made from thin tubes.
The joint is formed by further thickening or gear forming.
Challenge:

 Ring stretches during gear forming, leading to thinning and potential cracking.
Method c (Chosen Method):
Uses a stack of three sheets with different initial radii.
The strongest sheet (gear material) is in the center with a larger radius.
The stack is thickened and then gear-formed.
Advantages:

 Minimizes material waste.

 Center sheet prevents thinning and cracking.

 Most promising method for ISBMF hybrid gears.

Explanation of Method c:
Stack preparation: Three sheets are stacked with the strongest sheet (gear
material) in the center and larger in radius.
Thickening: The stack rotates while a tool radially thickens the center sheet,
spreading its material around the other sheets.
Gear forming: Gear teeth are formed incrementally using a dedicated tool. The
center sheet material helps maintain gear shape and prevent thinning.
Hybrid gears: Less force, stronger joints
This section explains the results and their significance:
Reducing Forming Force:
 Hybrid gears (steel + aluminum) require less force to shape compared to
all-steel gears (up to 30% less).
 This allows for using smaller or lighter forming tools, reducing cost and
extending tool life.
Stronger Joints:
 The way the hybrid gears are formed creates a strong bond between the
steel and aluminum layers.
 This bond is even stronger after the gear teeth are formed.
Two main factors contribute to the strong joint:
 Increased surface area due to gear teeth shape.
 "Micro-undercuts" formed during the shaping process, which lock the
materials together.
While there's no complete metal fusion, the joint is strong enough to handle
typical gear loads.
Material Distribution and Benefits:
 The forming process can control where the stronger steel material is placed
within the gear.
 This allows for optimizing the gear's strength and weight based on its specific
needs.
Overall, these results show that hybrid gears made with this new method offer
several advantages:
 They require less force to manufacture, reducing costs and tool wear.
 They have strong joints that can withstand typical gear loads.
 The material distribution can be customized for specific needs.
This research paves the way for lighter, stronger, and more efficient gears for
various applications!
Future works mentioned on the research article:
to understand exactly how these layers are joined together to further improve
the process.
They also want to use computers to simulate the forming process and predict
how different materials and designs will perform.
Overall, this research shows developing lighter, stronger, and more efficient
gears for various applications!
Thank you