Design for PM Challenges and Opportunities for Powder Metal Components in Transmission Technology

Abstract Powder metallurgy (PM) allows a resource and energy efficient production of drive train components. Due to the different process chain PM acts in a different design solution space than conventional manufacturing. An early cooperation between design and manufacturing engineers is mandatory to explore the potential for cost efficient solutions designed for manufacturing. PM offers a broad variety of material and heat treatment options. Tolerances need to be adapted to facilitate net-shaping and to avoid secondary operations. Size limitations are related to compaction forces and projected surface area. Net shaping enables lightweight design. This paper evaluates challenges and opportunities of drivetrain components made by PM. An insight of the technological principals will be given and rounded up by the illustration of cases from research and industrial practice. Gears, planetary carriers and clutch components will be covered. Design criteria like power density, NVH and lightweight will be considered and guidelines for daily work will provided.