Phoenix Sintered Metals
Customer Focused - Solution DrivenCase Studies
Process: CNC Press
Density: 6.9 g/cm3
Material: FL-4405 prealloyed steel
Gear Quality: ANSI/AGMA 2000-A88 class 7
End Use and Function
This component is a stepped planetary gear used in a ridged rear axle gear box for battery electric light commercial vehicles. To enable an 82:1 dual reduction planetary gear system, it was essential to be able to deliver tight dimensional control for this complex shaped part.
Fabrication
The concept was brought to fruition using CNC powder compaction. To enable an 82:1 dual reduction planetary gear system, it was essential to be able to deliver tight dimensional control for this complex shaped part. The five-level pinion, that has different tooth gear geometries on both ends, a 15-tooth and 18-tooth separated by a thin guiding flange that is used for orientation during assembly, exceeds ANSI/AGMA 2000-A88 class 7 requirements. Validation testing is performed by the end customer for performance, durability, reliability, and NVH (noise, vibration, and harshness). The FL-4405 prealloyed steel pinion undergoes quench & temper heat treatment prior to oil impregnation. This provides a robust wear resistant part with internal lubrication, with lower torque loss at start up and in cold weather conditions than grease, under normal operating conditions.
Results
No other metal forming technology could provide the part geometry at a commercially competitive price. The ability for PM to produce the stepped planetary configuration enabled the design to meet the overall required ration in a single planetary geartrain. This eliminated the complexity of the additional components to achieve the design goal. PM was the technology of choice.
Process: CNC Press
Density: 6.8 g/cm3
Material: FLC-4805
End Use and Function
The customer had started moving forward with 2 metal guides inside a plastic frame. This design had failed at a critical time in the launch plan. PM was brought in as the design of choice technology that was able to pass all testing and requirements in an accelerated timeline. The anti-rotation sleeve is part of the new drive by wire brake system introduced in production automotive vehicles for model year 2021. This evolution of vehicle safety in enhancing the previous ABS and traction control systems by actuation of the brake system with an electric motor vs the traditional vacuum boosted power brake pedal.
Fabrication
Density control is critical in minimizing form error through sintering and is formed using our CNC press. Maintaining part integrity through the compaction and ejection process is critical due to the thin cross section where the flange joins the legs. Parts are sinter hardened with custom design plates to support the legs to minimize distortion, maintaining tight perpendicularity and cylindricity, prior to a fully automated final hard turn machining operation controlling dimensions with 0.03 mm/0.0012”. The part is 100% verified during the machining operation for the OD fit and nut slot as well as resonant crack verification after sinter to ensure good product in this critical application.
Results
System provides enhanced safety combined with road and traffic monitoring systems to apply brakes before the driver can react in emergency conditions and is key to the development of future autonomous vehicles.
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