Surface Densified PM Gear Applied in E-axle Gearbox

PM technology is considered as a sustainable way of manufacturing high performance parts. Recently, the electrification trend in global industry requires rather higher performance and tighter tolerance of PM parts than ever. Therefore, a suitable manufacturing process needs to be selected based on the stringent component requirement, reaching near full density in the surface working area. This work presents an investigation on manufacturing, mechanical properties including durability bench test and NVH test of surface rolling densified gears aiming at high performance PM parts. The fatigue strength of standard PM FZG gear made by surface rolling densification exhibits comparable results to common steels. The bench test of surface rolling densified PM intermediate gear in reduction gearbox unit of BEV looks quite promising. Besides, PM gear could also have similar NVH performance and static load capacity like wrought steel gear.