Today's European gear manufacturers are
facing stiff competition from abroad while at the same time having
to meet increasingly strict environmental requirements. New laws
call for high-efficiency and low-noise engines, especially in trucks.
Consequently, there is now a high demand for a hard gear finishing
process which can provide excellent geometrical quality with low
noise behaviour at competitive costs.
This project resulted in a new low-speed
precision machining technology allowing economic production of high-quality
gears, mainly for automotive applications. A new test bench and
testing methodology were developed for tool specification. New software
for entering numerous geometrical and process parameters and for
visualising the manufacturing process were also developed. Finally,
a complex new-generation machining process known as low-speed shave-grinding
was used to produce high-quality gear wheels.
At the time of the study, say partners,
no data were available in the literature on low-speed grinding.
The new machining technology will provide a real boost to European
manufacturer trying to keep up with the competition. Cheaper grinding
equipment, shorter cycle times and lower total cost will save 20-30%
in operating costs. The commercial exploitation of the results began
before the end of the project.