EP1561832A1 - Verfahren zur Herstellung von sintergeharteten Teilen mit komplizierten Formen - Google Patents

Verfahren zur Herstellung von sintergeharteten Teilen mit komplizierten Formen Download PDF

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Publication number
EP1561832A1
EP1561832A1 EP05001266A EP05001266A EP1561832A1 EP 1561832 A1 EP1561832 A1 EP 1561832A1 EP 05001266 A EP05001266 A EP 05001266A EP 05001266 A EP05001266 A EP 05001266A EP 1561832 A1 EP1561832 A1 EP 1561832A1
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EP
European Patent Office
Prior art keywords
weight percent
compact
powder
grinding
parts
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP05001266A
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English (en)
French (fr)
Inventor
Ryan Sun
Kai Xu
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BorgWarner Inc
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BorgWarner Inc
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Filing date
Publication date
Application filed by BorgWarner Inc filed Critical BorgWarner Inc
Publication of EP1561832A1 publication Critical patent/EP1561832A1/de
Withdrawn legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12Both compacting and sintering
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12Both compacting and sintering
    • B22F3/16Both compacting and sintering in successive or repeated steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02Compacting only
    • B22F3/03Press-moulding apparatus therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24After-treatment of workpieces or articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/08Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of toothed articles, e.g. gear wheels; of cam discs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24After-treatment of workpieces or articles
    • B22F2003/247Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24After-treatment of workpieces or articles
    • B22F2003/248Thermal after-treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10Processes characterised by the sequence of their steps

Definitions

  • the invention pertains to the field of metallurgy. More particularly, the invention pertains to a method of producing a material from a metallurgical powder comprised of iron, carbon, nickel, molybdenum, and a combination of chromium, copper, manganese, and silicon.
  • Sinter hardening is a process used to produce a high martensite-content material without using a conventional heat treatment process, such as batch heat-treating or induction hardening.
  • the sinter hardening process comprises the steps of sintering the compact at an elevated temperature followed by rapidly cooling the compact at the end of sinter furnace hardening to induce martensite transformation.
  • Umeha et al U.S. 4,595,556
  • Method For Manufacturing Camshaft issued June 17, 1986.
  • Umeha et al disclose a method for producing members for fitting onto camshafts. After the pre-sinter step, the piece can be properly positioned on the shaft prior to sinter hardening. The compact is fifty percent axially shorter than the pre-sintered compact.
  • Saka et al . U.S. 5,049,183
  • Sintered Machine Part And Method issued September 17, 1991
  • the compact is repressed after the pre-sinter.
  • Such a method would be particularly applicable for producing synchronizer hubs for motorcars.
  • Seyrhunt (U.S. 5,659,873), Method Of Producing A Cam For A Jointed Camshaft, issued August 19, 1997, also describes a method, which includes a pre-sintering step. This method is used to produce a cam for a jointed camshaft. The pre-sintering step allows for the cam to be reworked to the desired contour, which may be lost during quenching and tempering.
  • Plamper U.S. 5,659,955
  • Method Of Making Powder Metal Helical Gears uses pre-sintering to produce a powder metal blank, which can be cold-rolled to make a helical gear with a helix angle greater than 35 degrees.
  • Standard powder metal compaction processes can not be used to make helical gears of a large helix angle.
  • Cadle et al . (U.S. 6,148,685), Duplex Sprocket/Gear Construction and Method of Making Same, issued November 21, 2000, use two metallurgical powder mixtures, one for the teeth and one for the body, to produce a sprocket.
  • the two powder alloys have properties tailored for local functional requirements of the final product.
  • the sintered body may be machined.
  • a method of producing parts from powdered metals comprising the following steps.
  • a metallurgical powder is provided, consisting of iron, 0.3-1.0 weight percent carbon, 0-4 weight percent chromium, 0-3 weight percent copper, 0.5-1.5 weight percent molybdenum, 0.5-4.5 weight percent nickel, 0-1.0 weight percent manganese, and 0-1.5 weight percent silicon.
  • Metal powders are made by atomization and mixing.
  • the powder metal parts are made by compacting, pre-sintering, profile/form grinding, sinter furnace hardening, and secondary operations.
  • Profile/form grinding generates profiles, which can not be formed by compaction tooling, such as undercut.
  • the specific pre-sinter cycle makes parts strong enough to withstand profile grinding but soft enough for easy grinding and prolonged grinding tool life. Powder metal parts made by this invention are also disclosed.
  • Metal powders are made by atomization and mixing.
  • the particulate materials consist of iron, 0.3-1.0 weight percent carbon, 0-4 weight percent chromium, 0-3 weight percent copper, 0.5-1.5 weight percent molybdenum, 0.5-4.5 weight percent nickel, 0-1.0 weight percent manganese, and 0-1.5 weight percent silicon. Table 1 lists the composition ranges for the particulate materials.
  • the powder possesses good sinter-hardening capabilities.
  • the process flow chart is shown in Figure 1.
  • the metallurgical powders are compacted (1) with a compaction pressure of 30 to 65 tons per square inch with a green density of 6.5 to 7.25 grams per cubic centimeter.
  • the green parts are pre-sintered (2) at a temperature from 1400 to 2000 degrees Fahrenheit.
  • Pre-sintering time is from 20 to 60 minutes.
  • Cooling rates vary from 10 degrees Fahrenheit per minute to 120 degrees Fahrenheit per minute to produce various microstructures such as Pearlite, Ferrite + Pearlite, and Bainite. When the cooling rate is greater than 120 degrees Fahrenheit per minute, Martensite, which is hard to machine, forms. Slow cooling (10 degrees Fahrenheit per minute) produces primarily a Pearlite microstructure.
  • Spheroidized Pearlite is best for machining.
  • the compact is cooled to ambient or nearly ambient temperatures.
  • Microstructure can be precisely achieved through control of pre-sintering temperature and cooling rate.
  • pre-sintering temperature and cooling rate As a result of the pre-sinter, the powder metal parts gain strength to make them strong enough for profile/form grinding (3).
  • the specific pre-sinter cycle also makes the particle hardness of the parts low to prolong the life of the grinding tool used during the profile/form grinding step.
  • Profile/form grinding utilizes super-abrasive tools to generate profiles and detailed geometry.
  • the process is also called Super Abrasive Machining (SAM).
  • SAM Super Abrasive Machining
  • Profile/form grinding is done after pre-sinter to produce various complex shapes such as multiple rows of teeth and undercut teeth, which are difficult to make by conventional powder metal compaction methods and single point machining.
  • the complexity of the shape is limited only by the size and precision of the profile and form grinding equipment.
  • parts are sinter furnace-hardened (4).
  • the sinter furnace hardening conditions are as follows: sintering temperature of 2000 degrees Fahrenheit to 2400 degrees Fahrenheit for 20 to 80 minutes, with a cooling rate of 120 to 450 degrees Fahrenheit per minute.
  • the final heat treatment is capable of producing greater than 90 percent Martensite, with a small amount of retained Austensite, Pearlite, and Bainite in the final powder metal part. Tempering, deburring, and other secondary operations (5) are optional depending upon final performance requirements.
  • This invention utilizes a special pre-sintering cycle (2) before profile/form grinding (3) and sinter furnace hardening (4). Pre-sintered parts are strong enough for profile/form grinding without breaking or chipping. Profile/form grinding (SAM) generates profiles and detailed geometry in a single operation. This method allows profile/form grinding to be done using less pressure and greater feed speed than when grinding regularly sintered parts. The invention also avoids the problem of grinding hardened powder metal parts.
  • the Gemini sprocket has two rows of teeth with a phase angle between the rows of teeth.
  • the Gemini sprocket design is disclosed in U.S. Patent No. 5,427,580, Phased Chain Assemblies, issued to Ledvina et al . on June 27, 1995.
  • the sprocket is part of a chain-drive system used in an automotive front-wheel drive transmission.
  • An advantage of the Gemini sprocket is reduced noise during operation. Considerations in material development include hardness/wear resistance and good hardenability.
  • the material containing iron, 2 weight percent copper, 0.8 weight percent carbon, 1.4 weight percent nickel, 1.25 weight percent molybdenum, and 0.42 weight percent manganese is pressed at a compaction pressure of 45 tons per square inch and pre-sintered at 1650 degrees Fahrenheit for 30 minutes.
  • the pre-sintered parts are cooled at 25 degrees Fahrenheit per minute.
  • the parts are then ground with a super-hard formed wheel to create two rows of teeth with a groove in between the rows.
  • the parts are sinter furnace hardened at 2070 degrees Fahrenheit for 30 minutes.
  • After sinter furnace hardening the parts are cooled at a rate of 150 degrees Fahrenheit per minute. As a secondary operation, deburring was performed.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
EP05001266A 2004-01-28 2005-01-21 Verfahren zur Herstellung von sintergeharteten Teilen mit komplizierten Formen Withdrawn EP1561832A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/766,154 US20050163645A1 (en) 2004-01-28 2004-01-28 Method to make sinter-hardened powder metal parts with complex shapes
US766154 2004-01-28

Publications (1)

Publication Number Publication Date
EP1561832A1 true EP1561832A1 (de) 2005-08-10

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EP05001266A Withdrawn EP1561832A1 (de) 2004-01-28 2005-01-21 Verfahren zur Herstellung von sintergeharteten Teilen mit komplizierten Formen

Country Status (5)

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US (1) US20050163645A1 (de)
EP (1) EP1561832A1 (de)
JP (1) JP2005213649A (de)
KR (1) KR20050077492A (de)
CN (1) CN1647874A (de)

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CN102654187A (zh) * 2011-03-04 2012-09-05 自贡市富源车辆部件有限公司 高精度低成本的油泵传动链轮加工方法
CN102654186A (zh) * 2011-03-04 2012-09-05 自贡市富源车辆部件有限公司 一种油泵传动链轮加工方法
CN102162070A (zh) * 2011-03-30 2011-08-24 中南大学 粉末冶金发动机连杆材料及其制备方法
KR101350944B1 (ko) * 2011-10-21 2014-01-16 포항공과대학교 산학협력단 분말사출성형용 철계 합금
KR101360422B1 (ko) * 2011-12-08 2014-02-11 기아자동차주식회사 시저스기어 구조 및 그 제조방법
CN102748281B (zh) * 2012-06-15 2015-07-01 扬州保来得科技实业有限公司 一种用于vvt技术的油泵转子及其制备方法
KR101405845B1 (ko) * 2012-08-10 2014-06-11 기아자동차주식회사 금속분말 사출 성형을 이용한 밸브 트레인 부품의 제조방법
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DE102013212528A1 (de) 2013-06-27 2014-12-31 Robert Bosch Gmbh Verfahren zur Herstellung eines Stahlformkörpers
CN104368816B (zh) * 2013-08-14 2016-12-28 东睦新材料集团股份有限公司 一种铁基粉末冶金零件的制造方法
CN103600065B (zh) * 2013-10-14 2016-04-13 富莱茵汽车部件有限公司 一种粉末冶金齿轮及其制备方法
JP6273869B2 (ja) * 2014-01-31 2018-02-07 セイコーエプソン株式会社 成形体の製造方法および構造体の製造方法
CN104827036A (zh) * 2015-05-11 2015-08-12 东睦新材料集团股份有限公司 一种铁基粉末冶金零件的制备方法
DE102015112322A1 (de) * 2015-07-28 2017-02-02 Hoerbiger Antriebstechnik Holding Gmbh Verfahren zum Herstellen eines Synchronrings sowie Synchronring
CN105624557A (zh) * 2016-02-22 2016-06-01 桐乡市搏腾贸易有限公司 一种机械传动链轮及其制造方法
CN106868419A (zh) * 2017-03-17 2017-06-20 江苏智造新材有限公司 粉末冶金质汽车自动变速箱驻车齿轮及其制备方法
US11097346B1 (en) * 2017-05-18 2021-08-24 Keystone Powdered Metal Company Process for manufacturing toroid parts
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CN110666176B (zh) * 2019-09-27 2022-04-29 无锡市恒特力金属制品有限公司 一种增强扭力和压溃强度的粉末冶金齿轮制造方法及应用
CN112647023A (zh) * 2020-12-14 2021-04-13 苏州莱特复合材料有限公司 一种汽车转向管柱吸能装置用齿条齿块及其生产工艺
CN113523285A (zh) * 2021-07-13 2021-10-22 扬州保来得科技实业有限公司 一种粉末冶金高密度多排齿链轮的制备方法
CN115889778A (zh) * 2023-01-05 2023-04-04 台州华联粉末冶金制品股份有限公司 一种齿轮的制备工艺

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JP2005213649A (ja) 2005-08-11
CN1647874A (zh) 2005-08-03
US20050163645A1 (en) 2005-07-28
KR20050077492A (ko) 2005-08-02

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