Lightweight construction of gear wheels using PBF-LB/M

© Fraunhofer IGCV
Procedure for the bionic lightweight optimisation of gears

Lightweight construction offers the possibility of reducing the masses and moments of inertia to be accelerated in the construction and manufacturing of gear wheels. This can improve resource efficiency and increase the performance of these parts.

In this project, production parameters for laser powder bed fusion are developed and optimized concerning the achievable component density and surface quality. The mechanical properties determined are all within the range of conventionally produced 16MnCr5 and indicate excellent material properties for gear production.

© Frauhofer IGCV
Gear wheel with a bionic lightweight structure made of 16MnCr5, manufactured using laser beam melting

The lightweight optimization is done using software-supported methods, such as topology optimization. On the other hand, methods of bionic optimization, which transfer solutions from nature into technical components, are used. Both approaches are employed to develop gears that have the potential to reduce the mass by up to 35%.



Binder, M.; Stapff, V.; Heinig, A.; Schmitt, M.; Seidel, C.; Reinhart, G. (2022): Additive manufacturing of a passive, sensor-monitored 16MnCr5 steel gear incorporating a wireless signal transmission system. In: Procedia CIRP 107, S. 505–510. DOI: 10.1016/j.procir.2022.05.016.

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Schmitt, Matthias; Gerstl, Florian; Boesele, Max; Horn, Max; Schlick, Georg; Schilp, Johannes; Reinhart, Gunther (2021a): Influence of Part Geometry and Feature Size on the Resulting Microstructure and Mechanical Properties of the Case Hardening Steel 16MnCr5 processed by Laser Powder Bed Fusion. In: Procedia CIRP 104, S. 726–731. DOI: 10.1016/j.procir.2021.11.122.

Schmitt, Matthias; Gottwalt, Albin; Winkler, Jakob; Tobie, Thomas; Schlick, Georg; Stahl, Karsten et al. (2021b): Carbon Particle In-Situ Alloying of the Case-Hardening Steel 16MnCr5 in Laser Powder Bed Fusion. In: Metals 11 (6), S. 896. DOI: 10.3390/met11060896.

Schmitt, Matthias; Jansen, Deniz; Bihlmeir, Andreas; Winkler, Jakob; Anstätt, Christine; Schlick, Georg et al. (2019): Rahmen und Strategien für den Leichtbau von additiv gefertigten Zahnrädern für die Automobilindustrie. In: Michael Kynast, Michael Eichmann und Gerd Witt (Hg.): Rapid.Tech + FabCon 3.D International Hub for Additive Manufacturing: Exhibition + Conference + Networking. München: Carl Hanser Verlag GmbH & Co. KG, S. 89–102.

Schmitt, Matthias; Kamps, Tobias; Siglmüller, Felix; Winkler, Jakob; Schlick, Georg; Seidel, Christian et al. (2020a): Laser-based powder bed fusion of 16MnCr5 and resulting material properties. In: Additive Manufacturing 35, S. 101372. DOI: 10.1016/j.addma.2020.101372.

Schmitt, Matthias; Michatz, Marco; Frey, Alexander; Lutter-Guenther, Max; Schlick, Georg; Reinhart, Gunther (2020b): Methodical software-supported, multi-target optimization and redesign of a gear wheel for additive manufacturing. In: Procedia CIRP 88, S. 417–422. DOI: 10.1016/j.procir.2020.05.072.



Dr.-Ing. Georg Schlick,, +49 821 90678-179