Manufacture of Copper-Niobium High-Intensity ADI Driving/Driven Spiral Bevel Gears for Load-Carrying Trucks

Abstract

This paper discusses utilizing Austempered Ductile Iron (ADI) to manufacture driving/driven spiral bevel gears for big-horsepower (under 350 Hp) heavy truck rear axles, which is a breakthrough in China. Through the carry out of focused research and experiments on main craft process key points of the components, and with all-round analysis to technical/quality outcome achieved, the authors have finally developed this new generation copper-niobium alloy ADI main/sub spiral bevel gear that is suitable for heavy truck (under 350 HP) rear axle uses. While being able to replace 22CrMo and 18CrMnTi alloy forged steels in use, this new gear has also achieved replacing forging & steel with casting & iron. Cutting of two main process steel-making and steel-rolling has not only raised production efficiency, but also lowered the its cost. At current, rear axle spiral bevel gears for automobiles in China are manufactured through forging, with 40Cr18CrMnTi22CrMo as key materials; cemented quenching and tempering techniques are applied in the production process.This method is also used in manufacturing of driving/driven spiral bevel gears for trucks rear axles. Such combination of high-quality steel and forging means high material cost, complicated process, and production inefficiency.