As manufacturing engineers in PM factory you will be planning the manufacturing

Question

As manufacturing engineers in PM factory you will be planning the manufacturing of two spur gears with the same geometry of 16 tooth of diametral pitch of 2 and 0.25 thickness. One gear is to be made using Alloyed steel powder (ss316L) and the other is made using Aluminum alloy powder (1050 aluminium alloy). If the customer for the alloyed steel gear orders 1M gear/year while the customer for the Aluminum alloy gear orders 100K gear/year, then conduct a basic research and analysis to provide/estimate the following

1. Force requirement for the press performing the compacting process and estimate the resulting green density

2. Sintering process and its parameter and an estimate for the resulting properties.

Explanation / Answer

GIVEN:- N = 16, PCD = 2" and Thickness of gear T = 0.25"

SOLUTION:-

(1) Area of the gear geometry under consideration A = 3.142 x (OD/2)^2

where OD = (N+2) x PCD/N = (16+2) x 2/16 = 2.25" And So A = 3.142 x (2.25/2)^2 = 3.98 in2 = 2567.74mm2

Typically the pressure (Pf) required in compacting for ss316L powder is 800 MPa and for 1050 aluminium alloy powder (Pa) is around 300 MPa.

So, force required for ss316L, Ff = Pf x A = 800 x 2567.74 = 2054.19 KN (ANSWER)

& Force required for 1050 Aluminium alloy Fa = Pa x A = 300 x 2567.74 = 770.32 KN (ANSWER)

Green density for ss316L = df = 0.95 x 7.9 = 7.5 g/cm3 (ANSWER)

& that for 1050 Aluminium alloy = da = 0.95 x 2.71 = 2.57 g/cm3 (ANSWER)

(2) Sintering process is a compacting process that is carried at a temperature below the melting point of the powder for certain amount of time and it helps in achieving a density of 100% with better ductility, tensile & fatigue strengths.

For ss316L temperature = 1275 K to 1425 K and time = 10 mins to 45 mins (ANSWER)

For 1050 Aluminium alloy temperature = 873 K and time = 20 mins (ANSWER)

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