An efficient and environmentally friendly way of manufacturing gears
EUREKA project E! 2339 EUROENVIRON GRINDING project has developed an alternative, flexible and environmentally friendly manufacturing technology for the production of gears that can reduce production times from months to a matter of days.
It can be used for all kinds of gears and joints made from treated alloyed steel, heat-resistant nickel or titanium alloys, such as those used in turbine and jet engine blades.
The current production process for industrial gears is expensive in terms of labour, materials and time. It involves the manufacture and maintenance of gear-cutting tools, the cutting and shaping of a blank and heat and thermo-chemical treatments. In comparison, the new process “is based on precision deep grinding by a shaped grinding wheel that improves both quality and productivity of the final gears. These unique tools are made by fusing abrasive grains of alumina corundum and silicon carbide to the surface of the tool with strong ceramic bonds,” says Josef Frumar, Production Manager at Czech lead partner Carborundum Electrite a.s.
The project partners hope that this new technique of grinding exact gear shapes may become an alternative to conventional practice which relies on distinct metalworking methods to obtain precision cutting edges. In Russia alone, the annual demand for grinding wheels is over 50,000 units. “The introduction and adoption of the new gear-manufacturing technology will make it possible to increase the production rates and quality of finished gear products,” concludes Frumar.
Carborundum Electrite a.s. may have 100 years of experience in the production of grinding wheels, but an unsuccessful privatisation trial during the last decade left it without an R&D department. “Our Russian partner carried out the fundamental research while we provided trial testing and implementation,” explains Frumar.
Prof. Viktor Starkov, Director of the Research Centre at the Moscow State Technical University, ’Stankin’, describes how it carried out most of the research work. “We developed various formulae for new high-porosity tools and conducted industrial tests in 14 Russian factories, together with theoretical analysis and experimental research, which created a basis for the development of this new technology of gear production by profile depth grinding.”
Frumar describes the benefits of being in a EUREKA project: “The EUREKA scheme provided the perfect chance for international co-operation on projects which will produce products that are the first on the market and ahead of our competitors.”
Julie Sors | alfa
The most recent press releases about innovation >>>
Die letzten 5 Focus-News des innovations-reports im Überblick:
An international team of scientists has proposed a new multi-disciplinary approach in which an array of new technologies will allow us to map biodiversity and the risks that wildlife is facing at the scale of whole landscapes. The findings are published in Nature Ecology and Evolution. This international research is led by the Kunming Institute of Zoology from China, University of East Anglia, University of Leicester and the Leibniz Institute for Zoo and Wildlife Research.
Using a combination of satellite and ground data, the team proposes that it is now possible to map biodiversity with an accuracy that has not been previously...
Heatwaves in the Arctic, longer periods of vegetation in Europe, severe floods in West Africa – starting in 2021, scientists want to explore the emissions of the greenhouse gas methane with the German-French satellite MERLIN. This is made possible by a new robust laser system of the Fraunhofer Institute for Laser Technology ILT in Aachen, which achieves unprecedented measurement accuracy.
Methane is primarily the result of the decomposition of organic matter. The gas has a 25 times greater warming potential than carbon dioxide, but is not as...
Hydrogen is regarded as the energy source of the future: It is produced with solar power and can be used to generate heat and electricity in fuel cells. Empa researchers have now succeeded in decoding the movement of hydrogen ions in crystals – a key step towards more efficient energy conversion in the hydrogen industry of tomorrow.
As charge carriers, electrons and ions play the leading role in electrochemical energy storage devices and converters such as batteries and fuel cells. Proton...
Scientists from the Excellence Cluster Universe at the Ludwig-Maximilians-Universität Munich have establised "Cosmowebportal", a unique data centre for cosmological simulations located at the Leibniz Supercomputing Centre (LRZ) of the Bavarian Academy of Sciences. The complete results of a series of large hydrodynamical cosmological simulations are available, with data volumes typically exceeding several hundred terabytes. Scientists worldwide can interactively explore these complex simulations via a web interface and directly access the results.
With current telescopes, scientists can observe our Universe’s galaxies and galaxy clusters and their distribution along an invisible cosmic web. From the...
Temperature measurements possible even on the smallest scale / Molecular ruby for use in material sciences, biology, and medicine
Chemists at Johannes Gutenberg University Mainz (JGU) in cooperation with researchers of the German Federal Institute for Materials Research and Testing (BAM)...