FE-based Layer Design of Deposition-Welded Semi-finished Parts for the Production of Hybrid Bevel Gear

Abstract Multi-material solutions offer numerous benefits as they, in contrary to conventional monolithic parts, represent tailor-made hybrid components with enhanced application-optimisation properties. The use of hybrid semi-finished products is the approach to apply the right material in the right place. This procedure of manufacturing components helps to reduce costs and avoids the waste of resources. Within this paper, a process route is presented, which can be used to produce a hybrid bevel gear by means of tailored forming technology. For the bevel gear, C22.8 was used as base material. The wheel body was designed with 41Cr4 and X45CrSi9-3. The semi-finished product was manufactured by means of deposition welding. The resulting geometry of the semi-finished product is a cylindrical body with two thin outer layers. This article focuses on the numerical investigation of the required layer thickness, so that on the one hand a material distribution after the forming process can be adjusted in order to guarantee the longest possible service life and on the other hand a stable forming process without cracks of the surface of the layers. Due to locally different material properties of the semi-finished product, uncommon material flow occurs. Furthermore, the deposition-welded material has different flow properties than conventional material. Therefore, a material characterisation by means of upsetting test was carried out for the 41Cr4 and X45CrSi9-3 in the deposition-welded status and was compared to conventional material. The initial thickness of the deposition-welded layers was designed with the aid of numerical simulation. The initial geometry of the layers was designed in such a way that the tooth body is completely filled after forming with an optimal use of material.