Abstract
Surface finish rolling experiments were carried out using P/M spur gears of 0.6Mo-0.2Mn pre-alloyed sintered steel and of 0.8Mo-0.2Mn partially alloyed sintered steel with the density of 7.10 Mg/m3. A CNC form rolling machine of axis intersection type was employed. Three kinds of screw-shaped rolling tools were prepared: one was an unmodified tool and the others were the modified tools for simultaneous rolling of tooth and fillet surface having concave tooth profiles optimized by numerical tooth profile analysis. Porosity distributions in the surface layer of rolled gear teeth were determined and the effects of the amount of tool radial feed R0 on the selective surface densification behaviors were evaluated. Single tooth bending fatigue test was conducted. Gears with good tooth profiles were obtained by using the modified tools. The porosities in both the tooth flank and the fillet at the root were reduced to the target level at R0=600 μm in simultaneous rolling process. The single tooth bending fatigue durability was much improved to the same level as that of the wrought steel gears of SCM415.
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