Nowadays, the bevel gears are widely applied in the industry for the intersected-axial transmission system. But the applications of the bevel gears are mostly limited to the usage of involute bevel gears. In this thesis, the bevel gear with circular-arc tooth profiles is derived by using general theorem of conjugate surfaces, coordinate transformation, constrained meshing equation, and spherical trigonometry. According to the bevel gears with circular-arc tooth profile derived above, the analyses and discussions of the interference are proposed. The interference situation is detected by applying the phase lead-lag concept while circular-arc curve is moving on the spherical cross-section. Furthermore, the ideal conditions to avoid occurrence of interference are proposed. Design charts for the maximum values of tooth profile angle are also constructed as a reference for designers. The 3D solid models of the bevel gear with circular-arc tooth profiles are constructed by using the computer software (Pro/E). Finally, the transmission ability is verified through the computer animation using CAE software (Visual Nastran). It is believed that the mathematical models and design method developed in the thesis will provide a useful foundation for the further studies.

The bevel gears have been widely used for the intersected-axial transmission system for a long time. But mostly them are limited in the category of involute tooth profiles. It is believed that bevel gears with circular-arc tooth profile, similar to the Wildhaber-Novikov circular-arc helical gears, will improve the load capacity of the gear set. The bevel gears with circular-arc tooth profiles was firstly proposed by Kuo and Tsai in 2001. Although these new type of bevel gears can increase the load capacity of transmission, the expensive manufacturing process is still the problem. In this paper, the design parameters of bevel gear with circular-arc profiles developed by Kuo and Tsai are modified. Bevel gear set with spiral point contact path is developed. This improvement makes it possible to manufacturing the newly developed bevel gears in just a simple milling or/and grinding process with circular cutting edges. The manufacturing process is then cost down quit a lot. A method for checking the gear interference is also proposed. Finally, the 3D solid models of the bevel gear with circular-arc tooth profiles as well as the grinding wheel are constructed by using the computer software ¡§Pro/E¡¨. It is believed that the mathematical models and the design method developed in the thesis will provide a useful foundation for the further studies.

Este trabalho propõe substituir o processo de usinagem que é empregado atualmente na fabricação de uma engrenagem cônica fabricada com material ABNT 8620, pelo processo de metalurgia do pó, gerando uma peça com economia de matéria prima, aumento de valor agregado e diminuição nos custos de produção. Esta peça tem como aplicação em um dispositivo utilizado na agroindústria destinado ao plantio, onde a engrenagem sofre esforços leves não necessitando ser tratada termicamente. A análise realizada neste trabalho tem como objetivo o desenvolvimento de um ferramental específico para a produção de uma engrenagem cônica sinterizada utilizando uma liga comercial da empresa Höganäs do Brasil denominada Distaloy AB, de composição Fe- Mo-Ni-Cu. As peças foram produzidas pelo processo de sinterização e analisadas em etapas diferentes do processo como: compactação, sinterização e calibragem. Na avaliação compara-se o diâmetro interno da engrenagem compactada, sinterizada e calibrada. Realizou-se um estudo dos valores de mercado entre os processos de usinagem e MP para um lote de produção de duas mil peças. As peças foram compactadas a 600MPa e sinterizadas a 1120oC, durante o tempo de 40min. Os resultados alcançados mostram a viabilidade de substituição do processo de usinagem pelo processo de metalurgia do pó para obtenção da peça de estudo, onde a economia de material e as propriedades mecânicas necessárias foram atingidas pelo componente sinterizado. / This work proposes to replace the machining process that is currently employed in the manufacture of a conical gear manufactured with ABNT 8620 material, by the process of powder metallurgy, generating a part with economy of raw material, increase of value added and decrease in production costs. This part is applied in a device used in the agroindustry destined to the planting, where the gear undergoes slight efforts not needing to be treated thermally. The analysis carried out in this work has the objective of developing a specific tooling for the production of a sintered conical gear using a commercial alloy of the company Höganäs do Brasil denominated Distaloy AB, with Fe-Mo-Ni-Cu composition. The pieces were produced by the sintering process and analyzed in different stages of the process as: compression, sintering and calibration. In the evaluation the internal diameter of the compacted, sintered and calibrated gear is compared. A study of the market values between the machining processes and MP for a production lot of two thousand pieces was carried out. The pieces were compacted at 600MPa and sintered at 1120oC for 40min. The results show the feasibility of replacing the machining process by the powder metallurgy process to obtain the study piece, where the material savings and the necessary mechanical properties were reached by the sintered component.

Le rendement d’un hélicoptère est étroitement lié à son poids. L’allègement des composants profite à la charge utile transportable. Il implique généralement une diminution de leur rigidité, donc une augmentation de leur déformation. Les boites de transmission par engrenages sont particulièrement concernées. Elles doivent assurer la transmission de puissances importantes à masse minimale. Les axes des roues dentées se désalignent alors progressivement au fur et à mesure de l’application du chargement. Les topographies des dentures spiroconiques sont corrigées pour tolérer ce déplacement et optimiser les performances du mécanisme. La portée d’engrènement ne doit pas toucher une arête afin d’éviter toute surpression par effet de bord et une dégradation prématurée des dents. Il faut améliorer la répartition de l’effort transmis et des pressions de contact. L’erreur de transmission induit des vibrations et du bruit. Il faut donc la minimiser. L’étude de la correction à appliquer à la denture est fastidieuse et requiert une longue période d’apprentissage lorsqu’elle est réalisée manuellement. Les travaux présentés s’inscrivent dans le cadre d’une automatisation du processus. L’usinage et l’engrènement des dentures sont simulés numériquement. Les méthodes proposées sont simples et robustes. Trois problèmes d’optimisation différents sont traités et analysés / The performance of a helicopter is closely linked to its weight. The components are lightened to benefit the carried payload. That usually involves a reduction in their stiffness, so an increase in their deformation. The transmission gear boxes are particularly affected. They must ensure the transmission of high powers with a minimal mass. The load makes the axes of the gears misaligned. The topographies of the spiral bevel gear teeth are corrected in order to tolerate the displacement and optimize the mechanism performances. The contact path must not touch tooth edges to avoid any overpressure and premature degradation. The distribution of the transmitted load and of the contact pressures must be improved. The transmission error induces vibrations and noise. Therefore, it must be minimized. The study of the correction to be applied to the teeth is tedious and requires a long learning period when it is done manually. The presented works fit into the scheme of an automated process. The machining and meshing of the teeth are simulated numerically. The proposed methods are simple and robust. Three different optimization problems are discussed and analyzed

Este trabalho propõe substituir o processo de usinagem que é empregado atualmente na fabricação de uma engrenagem cônica fabricada com material ABNT 8620, pelo processo de metalurgia do pó, gerando uma peça com economia de matéria prima, aumento de valor agregado e diminuição nos custos de produção. Esta peça tem como aplicação em um dispositivo utilizado na agroindústria destinado ao plantio, onde a engrenagem sofre esforços leves não necessitando ser tratada termicamente. A análise realizada neste trabalho tem como objetivo o desenvolvimento de um ferramental específico para a produção de uma engrenagem cônica sinterizada utilizando uma liga comercial da empresa Höganäs do Brasil denominada Distaloy AB, de composição Fe- Mo-Ni-Cu. As peças foram produzidas pelo processo de sinterização e analisadas em etapas diferentes do processo como: compactação, sinterização e calibragem. Na avaliação compara-se o diâmetro interno da engrenagem compactada, sinterizada e calibrada. Realizou-se um estudo dos valores de mercado entre os processos de usinagem e MP para um lote de produção de duas mil peças. As peças foram compactadas a 600MPa e sinterizadas a 1120oC, durante o tempo de 40min. Os resultados alcançados mostram a viabilidade de substituição do processo de usinagem pelo processo de metalurgia do pó para obtenção da peça de estudo, onde a economia de material e as propriedades mecânicas necessárias foram atingidas pelo componente sinterizado. / This work proposes to replace the machining process that is currently employed in the manufacture of a conical gear manufactured with ABNT 8620 material, by the process of powder metallurgy, generating a part with economy of raw material, increase of value added and decrease in production costs. This part is applied in a device used in the agroindustry destined to the planting, where the gear undergoes slight efforts not needing to be treated thermally. The analysis carried out in this work has the objective of developing a specific tooling for the production of a sintered conical gear using a commercial alloy of the company Höganäs do Brasil denominated Distaloy AB, with Fe-Mo-Ni-Cu composition. The pieces were produced by the sintering process and analyzed in different stages of the process as: compression, sintering and calibration. In the evaluation the internal diameter of the compacted, sintered and calibrated gear is compared. A study of the market values between the machining processes and MP for a production lot of two thousand pieces was carried out. The pieces were compacted at 600MPa and sintered at 1120oC for 40min. The results show the feasibility of replacing the machining process by the powder metallurgy process to obtain the study piece, where the material savings and the necessary mechanical properties were reached by the sintered component.

Este trabalho propõe substituir o processo de usinagem que é empregado atualmente na fabricação de uma engrenagem cônica fabricada com material ABNT 8620, pelo processo de metalurgia do pó, gerando uma peça com economia de matéria prima, aumento de valor agregado e diminuição nos custos de produção. Esta peça tem como aplicação em um dispositivo utilizado na agroindústria destinado ao plantio, onde a engrenagem sofre esforços leves não necessitando ser tratada termicamente. A análise realizada neste trabalho tem como objetivo o desenvolvimento de um ferramental específico para a produção de uma engrenagem cônica sinterizada utilizando uma liga comercial da empresa Höganäs do Brasil denominada Distaloy AB, de composição Fe- Mo-Ni-Cu. As peças foram produzidas pelo processo de sinterização e analisadas em etapas diferentes do processo como: compactação, sinterização e calibragem. Na avaliação compara-se o diâmetro interno da engrenagem compactada, sinterizada e calibrada. Realizou-se um estudo dos valores de mercado entre os processos de usinagem e MP para um lote de produção de duas mil peças. As peças foram compactadas a 600MPa e sinterizadas a 1120oC, durante o tempo de 40min. Os resultados alcançados mostram a viabilidade de substituição do processo de usinagem pelo processo de metalurgia do pó para obtenção da peça de estudo, onde a economia de material e as propriedades mecânicas necessárias foram atingidas pelo componente sinterizado. / This work proposes to replace the machining process that is currently employed in the manufacture of a conical gear manufactured with ABNT 8620 material, by the process of powder metallurgy, generating a part with economy of raw material, increase of value added and decrease in production costs. This part is applied in a device used in the agroindustry destined to the planting, where the gear undergoes slight efforts not needing to be treated thermally. The analysis carried out in this work has the objective of developing a specific tooling for the production of a sintered conical gear using a commercial alloy of the company Höganäs do Brasil denominated Distaloy AB, with Fe-Mo-Ni-Cu composition. The pieces were produced by the sintering process and analyzed in different stages of the process as: compression, sintering and calibration. In the evaluation the internal diameter of the compacted, sintered and calibrated gear is compared. A study of the market values between the machining processes and MP for a production lot of two thousand pieces was carried out. The pieces were compacted at 600MPa and sintered at 1120oC for 40min. The results show the feasibility of replacing the machining process by the powder metallurgy process to obtain the study piece, where the material savings and the necessary mechanical properties were reached by the sintered component.

The electrification of the automotive industry is the largest change in decades of the industry. This fact demands that established actors evaluate their current strategies and develop new competence. The engineering differences between conventional internal combustion engines vehicles and electric vehicles are many and significant. This means that strategies that made sense in past, needs to be reevaluated and recontextualized for today- and future needs. The goal of this case study was to create a basis from a ‘’birds eye view’’ of sourcing decisions for manufacturing companies. This case is designed based on Volvo Cars wishes and thoughts regarding the decision of in-house design and assembly of differential bevel gears. We believe that other manufacturing companies can use this report as a basis when faced with a similar sourcing decision. The basis of the case is qualitative, to get a thorough quantitative result, deeper investigation into engineering valus, economic impact and company-specific factors must be investigated. The study has been conducted in two parts, where the first part gives an understanding of the technical parameters to understand the process of the process of design and assembly of differential bevel gears. The second part examines, with the help of a business case, earlier case studies and compares the case company's situation and contextualize the wants and needs with a resource-based view and summarized through a SWOT-analysis to finally get a quantification with the help of a concept-decision matrix. Based on what the company's wishes were regarding a sourcing decision, a result could be determined in the form of a recommendation to the company. The results showed that insourcing would benefit the company. This is partly due to the fact that they would get cross-functional knowledge and that a collaboration between design and assembly would benefit the final product, the end-customer and therefore the company at large. The results from the concept matrix indicate that the company should choose the insourcing strategy. But there are many parameters to consider. What is not addressed in this report are the economic impact compared to the technical and organizational gains of an insourcing decision, which could be researched in future studies. / Elektrifieringen av fordonsindustrin är den största förändringen på decennier för bilindustrin. Detta kräver att etablerade aktörer utvärderar sina nuvarande strategier och utvecklar ny kompetens, eftersom de tekniska skillnaderna mellan konventionella förbränningsmotorer och elfordon är många och betydande. Detta innebär att strategier som var lämpliga i det förflutna måste omvärderas och omkontextualiseras för dagens och framtida behov. Målet med denna fallstudie var att skapa ett underlag för inköpsbeslut för tillverkande företag. Detta är utformat utifrån Volvos önskemål och tankar kring beslutet att insourcing precisionssmidda koniska växlar. Vi tror att andra tillverkningsföretag kan använda denna rapport som grund när de står inför ett liknande inköpsbeslut. För att få ett fullständigt resultat måste djupare undersökning av ekonomi, tekniska möjligheter och företagsspecifika faktorer undersökas. Studien har genomförts i två delar, där den första delen ger en förståelse för de tekniska parametrarna. Den andra delen har granskat tidigare inköpsbeslut som jämförts med det undersökta företagets situation och framtida mål. Utifrån vad bolagets önskemål var gällande ett inköpsbeslut kunde ett resultat fastställas i form av en rekommendation till företaget. Resultaten visade att insourcing skulle gynna företaget. Detta beror på att de skulle få tvärfunktionell kunskap och att ett samarbete mellan design och montering skulle gynna slutprodukten. Resultaten från konceptmatrisen indikerar att företaget bör välja insourcingstrategi. Men det finns många parametrar att tänka på. Vad som inte tas upp i denna rapport är de ekonomiska aspekterna av ett insourcingbeslut, som kan undersökas i framtida studier.

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