Quiet Gear Wheel and Method for Producing Such a Gear Wheel

• US 20180017150A1
• Filed: 02/01/2016
• Published: 01/18/2018
• Est. Priority Date: 02/03/2015
• Status: Active Grant

• Current Assignee: Gkn Sinter Metals Engineering Gmbh (Melrose Industries Plc)
• Original Assignee: Gkn Sinter Metals Engineering Gmbh (Melrose Industries Plc)
• Inventors: Leupold, Bjrn, Hges, Simon, Schneider, Markus, Schupp, Thomas, Janzen, Vitali, Kotthoff, Gerd, Ernst, Eberhard
• Granted Patent: US 10,890,241 B2
• Time in Patent Office: Days
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 3/1109 Inhomogenous pore distribution composite layers of porous nature B22F7/002
• CPC Class Codes: B22F 3/1112 comprising hollow spheres or hollow fibres
• CPC Class Codes: B22F 3/1118 comprising internal reinforcements
• CPC Class Codes: B22F 5/08 of toothed articles, e.g. gear wheels; of cam discs
• CPC Class Codes: B22F 7/002 of porous nature
• CPC Class Codes: B22F 7/08 with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F16H 55/06 Use of materials; Use of treatments of toothed members or worms to affect their intrinsic material properties coatings for lubrication F16H57/041; producing gear wheels from plastics or substances in a plastic state B29D15/00; heat treatment C21D9/32; electrolytic surface treatment C25D; heating by electromagnetic field H05B6/00
• CPC Class Codes: F16H 55/14 Construction providing resilience or vibration-damping F16H55/06 takes precedence
• CPC Class Codes: F16H 57/0006 Vibration-damping or noise reducing means specially adapted for gearings devices for varying tension of belts, ropes or chains with damping means F16H7/0829; toothed members with construction providing vibration damping F16H55/14; reducing vibrations or noise of the gearbox casing F16H57/028; suppression of vibrations or noise of gear selectors F16H59/0208; control of hydrostatic fluid gearing preventing or reducing vibrations or noise F16H61/4183
• CPC Class Codes: G10L 21/0208 Noise filtering
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The present invention relates to a gear wheel containing at least one sintered material having a porosity, the gear wheel having, in addition to the porosity, another noise-reducing means.

Claims

1. A gear wheel comprising at least one sintered material with a porosity, wherein the gear wheel has, in addition to the porosity, another noise reducing structure.

2. The gear wheel as claimed in claim 1, wherein an at least partially acoustic decoupling of a tooth ring of the gear wheel and a hub is produced, along with a refraction of sound waves by a variation of density in the wheel body, which interrupts a transmission path of the structure-borne sound waves from the generation at the tooth ring to the hub and/or refracts, absorbs or reflects sound waves so that a structure-borne sound signal at an output in the form of a shaft of the gear wheel or a bore of the gear wheel seems less pronounced.

3. The gear wheel as claimed in claim 1, wherein there is a radial variation of a density in a wheel body of the gear wheel.

4. The gear wheel as claimed in claim 1, wherein a structure-borne sound is refracted, absorbed and/or reflected by chambers which are introduced in a wheel body of the gear wheel.

5. The gear wheel as claimed in claim 4, wherein the chambers are empty and/or filled with a medium selected from an oil and/or a loose powder.

6. The gear wheel as claimed in claim 1, wherein the gear wheel has at least one or more of the following noise reducing structures:

a refraction, an absorption and/or reflection of sound waves by filled and/or unfilled chambers in the gear wheel,

a combination of different densities and/or materials which extend in the radial direction to form ring-shaped, rings of different density and/or materials.

7. The gear wheel as claimed in claim 1, wherein an axial density variation is provided.

8. The gear wheel as claimed in claim 7, wherein the gear wheel has a disk-like construction of different densities.

9. The gear wheel as claimed in claim 1, wherein a sound channel runs in the gear wheel along which a structure-borne sound is guided.

10. The gear wheel as claimed in claim 9, wherein specifically introduced conduits as noise channels hinder a structure-borne sound from getting directly to an output in the form of a shaft or bore of the gear wheel.

11. The gear wheel as claimed in claim 9, wherein a material with a higher density forms the sound channel.

12. The gear wheel as claimed in claim 9, wherein the sound channel is provided with a material identical to the surroundings of the sound channel with a lesser porosity.

13. The gear wheel as claimed in claim 9, wherein the sound channel has rotational symmetry about an axis of rotation of the gear wheel.

14. The gear wheel as claimed in claim 1, wherein the gear wheel has a vibration-dampening coating.

15. The gear wheel as claimed in claim 1, wherein the gear wheel has a bracing, while the braces of the bracing have a vibration-dampening coating.

16. The gear wheel as claimed in claim 1, wherein one or more asymmetrical geometries are present in the gear wheel, which influence an eigenfrequency of the gear wheel.

17. The gear wheel as claimed in claim 1, wherein the gear wheel has a quality grade of the designed gear wheel per DIN 3961 and DIN 3962 in terms of at least one parameter selected from a total profile error F_a, a profile angle error f_Ha and/or a profile form error f_a, of at least the gearing quality 6 or better.

18. A method for production of a gear wheel comprising the following steps:

designing a sintered gear wheel using predetermined geometry and loading data,

simulating a load computation and a noise prediction for the designed gear wheel,

selecting at least one noise reducing structures as claimed in claim 1,

verifying a load computation and a noise prediction,

adapting of the gear wheel if necessary and repeating of at least the verifiying of the noise prediction or the load computation,

drafting of manufacturing data and manufacturing of the gear wheel on the basis of the manufacturing data.

19. The method as claimed in claim 18, wherein several different noise reducing structures are simulated until a choice of one or more noise reducing structures is made with the aid of predetermined criteria.

20. The method as claimed in claim 18, wherein a quality grade of the designed gear wheel per DIN 3961 and DIN 3962 in terms of one parameter selected from a total profile error F_a, a profile angle error f_Ha and a profile form error f_a, is adapted each time to the gearing quality 6 or better.

21. The method for production of a gear wheel as claimed in claim 18, wherein a selection of a manufacturing method is made from predetermined manufacturing technology, load analysis, and noise abatement aspects.

22. The method for production of a sintered gear wheel as claimed in claim 1, wherein at least one of the following manufacturing methods is used to form a noise reducing structure in the gear wheel:

a surface rolling and/or surface compacting of the teeth to adjust a porosity from noise reduction aspects,

a simultaneous arrangement of two or more different powders to be sintered jointly in the same pressing mold for the forming of a noise reducing structure in the gear,

inserting of one or more bodies in and/or on a material to be sintered of the gear wheel to be produced, selected from a brace, a vibration system, a hollow body or a fluid-filled body.

23. A computer program product for the production of a gear wheel with computer program code on a data medium for executing a method as claimed in claim 18.

24. (canceled)