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In den vergangenen Jahrzehnten sind die aktuellen Auslegungsgrundlagen für Mitnehmerverzahnungen in Zahnkupplungen erarbeitet und für die praktische Anwendung nutzbar aufbereitet worden. Ein seit jeher bestehendes Problem aber ist die nicht prognostizierbare Verschleißerscheinung Fressen innerhalb der Verzahnung. Diese Unkenntnis erschwert eine zuverlässige, betriebssichere Bemessung von Zahnkupplungen in hohem Maße. Die vorliegende Arbeit behandelt die Entwicklung eines Berechnungsansatzes zur Bestimmung der Fresstragfähigkeit von verlagerungsfähigen Mitnehmerverzahnungen in ölgefüllten Zahnkupplungen. Sie leistet damit einen Beitrag zur Erweiterung der bestehenden Bemessungsmethode und bietet für weiterführende Forschungstätigkeiten eine substanzielle Grundlage. / Over the past decades, the current design bases of gear coupling indentations have been developed and prepared for practical application. Nevertheless, scuffing is one of the most considerable design problems, due to the fact that it is not predictable. This lack of knowledge complicates a reliable and fail-safe dimensioning crucially. The presented dissertation deals with the formulation of a calculation approach concerning the determination of scuffing load capacity of displaceable indentations in oil-filled gear couplings. It contributes to the enhancement of the current method of structural design and it serves a substantial basis for further research projects.

In den vergangenen Jahrzehnten sind die aktuellen Auslegungsgrundlagen für Mitnehmerverzahnungen in Zahnkupplungen erarbeitet und für die praktische Anwendung nutzbar aufbereitet worden. Ein seit jeher bestehendes Problem aber ist die nicht prognostizierbare Verschleißerscheinung Fressen innerhalb der Verzahnung. Diese Unkenntnis erschwert eine zuverlässige, betriebssichere Bemessung von Zahnkupplungen in hohem Maße. Die vorliegende Arbeit behandelt die Entwicklung eines Berechnungsansatzes zur Bestimmung der Fresstragfähigkeit von verlagerungsfähigen Mitnehmerverzahnungen in ölgefüllten Zahnkupplungen. Sie leistet damit einen Beitrag zur Erweiterung der bestehenden Bemessungsmethode und bietet für weiterführende Forschungstätigkeiten eine substanzielle Grundlage. / Over the past decades, the current design bases of gear coupling indentations have been developed and prepared for practical application. Nevertheless, scuffing is one of the most considerable design problems, due to the fact that it is not predictable. This lack of knowledge complicates a reliable and fail-safe dimensioning crucially. The presented dissertation deals with the formulation of a calculation approach concerning the determination of scuffing load capacity of displaceable indentations in oil-filled gear couplings. It contributes to the enhancement of the current method of structural design and it serves a substantial basis for further research projects.

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This Master's thesis project was provided by Epiroc Rock Drills AB and conducted at Camatec Industriteknik AB in Karlstad, Sweden. The project is centered around the cutter wheel in the mechanical rock excavator Mobile Miner 40V.  This cutter wheel is equipped with cutter discs that grind rock into debris as the wheel rotates and thrusts forward. The internal system consisting of a bearing constellation and the components in its vicinity has experienced a certain degree of wear in the form of scuffing and this was detected on the surfaces of some of the components in the system. The reasons for this occurrence are unknown and per the request of the thesis provider, this was to be determined. The thesis provider also requested a new Finite Element Analysis (FEA) model of the system along with feasible load cases that can be applied to said model. The project was deemed extensive and was therefore decided to be conducted by two students. This thesis covers the determination of the load cases as well as the optimization of the current design of the system inside the cutter wheel. During the pre-study, relevant background data was obtained for the cutter wheel and the internal system. Methods and models considered to potentially be useful were also gathered. The system in question was divided into two separate models; one consisted of a tribo-system with two components in sliding contact and the other consisted of the bearing constellation along with the outer-most section of the cutter wheel. The purpose of the first model was to use it to determine the contact pressure between the tribo-surfaces and by doing so, be able to determine the expected lubrication regime for the oil in the tribo-system. A material selection process was also conducted on the tribo-surface that had experienced the most severe surface damage. Additionally, minor reconstructions were made with the purpose of optimizing the system. The purpose of the second model was to apply the calculated load cases to the cutter disc attachments located on the outer-most section of the cutter wheel and then determine the contact pressures that develop on the bearing roller elements. The results of the thesis work consist of five potential material options, two reconstructions and 60 different load cases for the FEA model. With the load cases, the largest contact pressures on the bearing roller elements was determined. In addition, the cause of the severe surface damage that had occurred in the system is believed to have been identified. Further work on the project work is believed to be required. Future work of interest are determining load cases that incorporate multiple cutter discs simultaneously in contact with the rock, reconstruction solutions for the oil inlet and outlet pipes, a more thorough materials selection process and a criterion for the expected lubrication regime in the tribo-system based on tests performed with materials that are more identical to the ones in this project. / Detta examensarbete tillhandahölls av Epiroc Rock Drills AB och genomfördes hos Camatec Industriteknik i Karlstad, Sverige. Projektet är centrerat kring cutterhjulet i maskinen Mobile Miner 40V som är avsedd för mekanisk bergavverkning. Cutterhjulet är utrustat med cutter discar som maler berget till mindre flisor genom att hjulet roterar och trycks framåt. Det inre systemet bestående av en lagring med närliggande komponenter har utsatts för en viss grad av nötning i form av scuffing och detta upptäcktes på ytorna hos vissa av komponenterna i systemet. De bakomliggande anledningarna för denna förekomst är okända och utifrån begäran från projektgivaren skulle dessa anledningar fastställas. Projektgivaren eftersökte även en ny FEM-modell av systemet tillsammans med rimliga lastfall som ska kunna appliceras på modellen i fråga. Projektet ansågs tämligen omfattande och det bedömdes därför att två studenter krävdes för att genomföra arbetet. Denna uppsats behandlar framtagningen av lastfallen såväl som optimeringen av den nuvarande designen av systemet inuti cutterhjulet. Under förstudien hämtades relevant bakgrundsdata för cutterhjulet och det interna systemet. Metoder och teorier som ansågs vara potentiellt användbara samlades även in. Systemet i fråga delades in i två separata modeller; en bestod av ett tribo-system bestående av två tribo-ytor i glidande kontakt och den andra bestod av lagringen tillsammans med den yttersta sektionen hos cutterhjulet. Syftet med den förstnämnda modellen var att använda den för att bestämma kontakttrycket mellan tribo-ytorna, och genom detta kunna fastställa den förväntade smörjningsregimen hos oljan i tribo-systemet. En materialvalsprocess utfördes även för tribo-ytan som hade utsatts för den mest allvarliga skadan. Även smärre omkonstruktioner utfördes med syftet att optimera systemet. Syftet hos den andra modellen var att kunna applicera de beräknade lastfallen på cutter discarnas infästningar som återfinns i den yttersta sektionen hos cutterhjulet och sedan bestämma kontakttrycken som uppstår på rullarna i lagren. Resultaten från arbetet består av fem potentiella materialval, två konstruktionsändringar och 60 olika lastfall för FEM-modellen. Genom att applicera lastfallen bestämdes de största kontakttrycken på lagrens rullar. Utöver detta anses det att anledningen för den allvarliga ytskadan som hade skett i systemet har identifierats. Det anses att fortsatt arbete krävs för projektet. Kompletterande arbete som anses vara av intresse är lastfall som inkluderar flera cutter discar i ingrepp samtidigt med berget, konstruktionslösningar för tillförsel och bortförsel av oljan, en mer djupgående materialvalsprocess och ett kriterium för förväntad smörjningsregim hos tribo-systemet baserat på tester utförda med material som är mer identiska med dem som förekommer i projektet.

<p>Abstract</p><p>Today sheet metal forming is used to make a variety of mass production because it has a high production rate. One of the biggest concerns in sheet metal forming is wear of the tool in form of galling. Galling in sheet metal forming is characterised by an increased tool surface roughness, unstable friction in the forming process and undesirable scratches on the final products.</p><p>Several ways of ranking materials resistance to galling exist today but only ASM G98 is standardised. Nevertheless, some different methods developed for ranking tool materials’ tendency to galling have also been developed.</p><p>The aim of this thesis is to develop and improve the Uddeholm Tooling Tribo Test rig located at Uddeholm Tooling AB. The rig, which is a variation of cylinder-on-cylinder test equipment, was improved with a new tool holder, a utilization of the real sheet material counter face and a new data acquisition system and software. The galling was detected using scratches on the sheet, metallographic analysis of the material adhered on the tool specimen, monitoring of coefficient of friction and the standard deviation of the coefficient of friction.</p><p>The obtained results show difficulties with ranking of tool materials in terms of galling resistance under non-lubricated conditions. The tool steels tested were SVERKER21 and UNIMAX. AISI304-10, DC04 and DOCOL1000DP sheets were used. Additionally a low friction coating of BalinitC on SVERKER21 was also included. All specimens of the tool steels showed signs of galling on every run, only the low friction coating showed a transition in behaviour of friction coefficient corresponding to galling initiation. The standard deviation of the coefficient of friction increased at low loads. A decrease of the test loads led to stability loss of the system detected by an increase in the standard deviation of the coefficient of friction. This might happen because the Kistler platform is originally designed for larger loads. Although, the test rig does not work properly in its present state, the concept looks promising.</p>

Abstract Today sheet metal forming is used to make a variety of mass production because it has a high production rate. One of the biggest concerns in sheet metal forming is wear of the tool in form of galling. Galling in sheet metal forming is characterised by an increased tool surface roughness, unstable friction in the forming process and undesirable scratches on the final products. Several ways of ranking materials resistance to galling exist today but only ASM G98 is standardised. Nevertheless, some different methods developed for ranking tool materials’ tendency to galling have also been developed. The aim of this thesis is to develop and improve the Uddeholm Tooling Tribo Test rig located at Uddeholm Tooling AB. The rig, which is a variation of cylinder-on-cylinder test equipment, was improved with a new tool holder, a utilization of the real sheet material counter face and a new data acquisition system and software. The galling was detected using scratches on the sheet, metallographic analysis of the material adhered on the tool specimen, monitoring of coefficient of friction and the standard deviation of the coefficient of friction. The obtained results show difficulties with ranking of tool materials in terms of galling resistance under non-lubricated conditions. The tool steels tested were SVERKER21 and UNIMAX. AISI304-10, DC04 and DOCOL1000DP sheets were used. Additionally a low friction coating of BalinitC on SVERKER21 was also included. All specimens of the tool steels showed signs of galling on every run, only the low friction coating showed a transition in behaviour of friction coefficient corresponding to galling initiation. The standard deviation of the coefficient of friction increased at low loads. A decrease of the test loads led to stability loss of the system detected by an increase in the standard deviation of the coefficient of friction. This might happen because the Kistler platform is originally designed for larger loads. Although, the test rig does not work properly in its present state, the concept looks promising.