Net-shape gears made of high-strength steels by oscillating forming

Substituting heat treatment processes in the existing process chain by the use of cold hardening during the forming process represents a central goal of this project. Using special material conditions the hardening of the splines after the forming process is to be saved. As a result, the component quality can be increased and leads to a cost reduction. In addition, the forming process is supported by a process control.


By means of oscillating forming processes, high-precision components can be produced economically. For the gear production, the effect of the re-lubrication is used to reduce the occurring forces. Thus, the process limits can be extended. Typical components can be found in car transmissions, so-called splines being produced by this method. In the current process chain, various heat treatments are necessary in order to prepare the material for the forming process and to achieve the required hardness. These process steps extend the component costs and increase the required energy for the production. From today's point of view these steps are necessary to prepare the workpiece for the forming and to ensure the durability of the components.

[1] Gear forming tool


To achieve the aim, materials are thermomechanically hot-rolled in cooperation with the Institute IMF Freiberg after a numerical process design. In addition, the tribological properties of the different semifinished products are analyzed. Furthermore, the implementation of a force control of the testing press enables optimization of the loads during the forming process. For this purpose, a new oscillation cycle is started when a defined force is reached whereby a re-lubrication of the forming zone with oil occurs. As a result, the tool loads can be optimized. Thus, high strengh steel can be formed and no more heat treatment is required in the process chain.

[2] State of the art and new process chain


The IGF-Research Project 19557 ZB, supported by the GCFG, is funded in the scope of the “Progamm zur Förderung der Industiellen Gemeinschaftsforschung” (IGF) via the German Federation of Industrial Research Associations (AiF) by the German Ministry for Economy and Energy as decided by the German parliament.

Furthermore, we thank all involved companies for the support of the research project.

  • Advanced Tooling Solutions ApS
  • ConSenses GmbH
  • CPM GmbH
  • Felss Systems GmbH
  • Schondelmaier GmbH Presswerk
  • simufact engineering GmbH
  • Zeller+Gmelin GmbH & Co. KG
  • ZF Friedrichshafen AG
  • Zwez-Chemie GmbH