Application Center Automotive / Dr.-Ing. Stefan Scherbarth

Projects – customer & component focused Machining of the friction welding seam of layshaft wheel

• A reliable process for machining the friction welded should be developed.

• Focus is to avoid the „ring“ formation during the classical turning process (see next slide).

Tests performed:• Turn-milling one hit operation

• Slotting of the welded seam and turning of the area.

Project goal:

Material: 25MoCr4

For the truck component plant in Gaggenau, Germany Daimler AG will invest into a new lathe for machining friction welded hollow gears for the layshaft.

Application Center Automotive / Dr.-Ing. Stefan Scherbarth

Initial situation

With the conventional turning process at the end of the cut a ring is formed. The uncontrolled ring formation destroys the cutting edge.

The process reliability is low.

Gap between welding zone

and workpiece

Application Center Automotive / Dr.-Ing. Stefan Scherbarth

Customer project - table layshaft wheel Best possible solution - turn-milling

- no ring formation - short machining time (30 s)- high reliability incl. chip evacuation- only one tool necessary

• For machining the friction welding seam on Mulit-Task-Machines, turn-milling is the best possible solution.

Application Center Automotive / Dr.-Ing. Stefan Scherbarth

Customer project - table layshaft wheel Alternative solution - slitting and turning• For machining the table layshaft wheel on a lathe with driven unit,

slitting and turning of the welded seam is an alternative solution.

- 33% longer machining time (42 s)- two tools are needed

Step 1 : Slitting of welded seam Step 2 : Classic turning

Application Center Automotive / Dr.-Ing. Stefan Scherbarth

Customer project - table layshaft wheel