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<p>Low-alloy steels have become a&#xa0;mainstay in critical components like gears and shafts, due their cost-effectiveness and desirable mechanical properties. However, their inherent limitations highlight the need for innovative solutions to enhance their mechanical properties, particularly for applications demanding exceptional performance and durability. In all manufacturing processes, there are active forces to make the desired transformation of a&#xa0;given material, generating friction and, consequently, heat, to provide the formation, or not, of a&#xa0;chip. When these forces cease to act on the material, that is, when it remains at rest, residual stress is generated due to the efforts that led to the change in its structure (crystalline lattice). Stresses have a&#xa0;major effect on the physical, mechanical and chemical properties of the surface layer. Therefore, an appropriate residual stress can be obtained by selecting appropriate process parameters. Several studies have investigated the effect of machining processes separately on residual stress behavior. Based on this, this study aims to contribute to the advancement of research in gear manufacturing by presenting an investigation conducted in the automotive industry, in which residual stress was evaluated sequentially as a&#xa0;function of each stage of the manufacturing process—hobbing → shaving → carbonitriding—in manual transmission reduction gears manufactured from low-carbon manganese steel. It was demonstrated that different types of residual stresses are intrinsic to certain stages of the manufacturing process and that their transformations are interdependent, almost like a&#xa0;“memory” accumulated in each constructive phase of the component.</p>

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Analysis of residual stress in helical gear teeth involute profile and helix in hobbing, shaving, carbonitriding, quenching and tempering processes

  • 期刊论文

  • 发表日期：

    2025年11月27日

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  • Carlos Alberto de Sousa Neves,
  • José Rubens Gonçalves Carneiro,
  • Gilmar Cordeiro da Silva,
  • Paulo Sérgio Martins,
  • Elhadji Cheikh Talibouya Ba,
  • Pedro Miraglia Firpe,
  • Anderson Silva José,
  • Leandro da Silva Braga,
  • Daniel Moreira Miranda

摘要

Low-alloy steels have become a mainstay in critical components like gears and shafts, due their cost-effectiveness and desirable mechanical properties. However, their inherent limitations highlight the need for innovative solutions to enhance their mechanical properties, particularly for applications demanding exceptional performance and durability. In all manufacturing processes, there are active forces to make the desired transformation of a given material, generating friction and, consequently, heat, to provide the formation, or not, of a chip. When these forces cease to act on the material, that is, when it remains at rest, residual stress is generated due to the efforts that led to the change in its structure (crystalline lattice). Stresses have a major effect on the physical, mechanical and chemical properties of the surface layer. Therefore, an appropriate residual stress can be obtained by selecting appropriate process parameters. Several studies have investigated the effect of machining processes separately on residual stress behavior. Based on this, this study aims to contribute to the advancement of research in gear manufacturing by presenting an investigation conducted in the automotive industry, in which residual stress was evaluated sequentially as a function of each stage of the manufacturing process—hobbing → shaving → carbonitriding—in manual transmission reduction gears manufactured from low-carbon manganese steel. It was demonstrated that different types of residual stresses are intrinsic to certain stages of the manufacturing process and that their transformations are interdependent, almost like a “memory” accumulated in each constructive phase of the component.