Gear Hobbing Predictive Model

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N68335-10-C-0448
Agency Tracking Number: N102-122-0783
Amount: $149,942.00
Phase: Phase I
Program: SBIR
Awards Year: 2010
Solicitation Year: 2010
Solicitation Topic Code: N102-122
Solicitation Number: 2010.2
Small Business Information
7900 West 78th St., Suite 300, Minneapolis, MN, 55439
DUNS: 938966090
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Troy Marusich
 Chief Technical Officer
 (952) 832-5515
Business Contact
 Lisa Ferris
Title: Chief Operating Officer
Phone: (952) 832-5515
Research Institution
This program will demonstrate the feasibility of innovative physics-based modeling of gear hobbing to predict and improve residual stresses and heat treat distortions while reducing production cycle times and costs of transmission gears. TWS will develop a general, validated, physics-based modeling capability for the gear hobbing process, resulting in detailed chip formation and residual stress prediction. This will be achieved through both a detailed finite element modeling of tool-workpiece interaction, and CNC toolpath-level analysis. The combined outputs of these comprehensive models will provide the ability to predict machining-induced residual stresses and their effects on distortion from subsequent heat treatment, and determine interactions between machining process changes and cost, cycle time and workpiece characteristics. Feasibility will be demonstrated by: 1) advancing physics-based machining modeling for gear hobbing processes, 2) developing physics-based gear hobbing predictive models based on finite element modeling, and 3) validating these physics-based models against machining experiments. Anticipated results results of the program will: (1) predict residual stresses, forces, temperatures, and tooling performance for hobbing; (2) improve fatigue life of gear components through residual stress management while reducing cycle times and cost; and (3) advance knowledge of material removal mechanisms in gear hobbing and their effects on post-machining operations.

* Information listed above is at the time of submission. *

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