The Relevance of a Comprehensive Approach to Residual Stress Analysis in Drivetrain Components

The design of drivetrain components has become increasingly challenging with the energy transition, given the demand for higher power density in combination with refined noise, vibration, and harshness (NVH) behavior while minimizing power losses. This scenario highlights the critical nature of residual stress (RS) as a decisive property to enable superior performance. The

objective of this article is to highlight the fact that the RS state in drivetrain components goes well beyond a mean surface value. Its structure explores the broad range of features needed to properly describe the RS state, including in-depth profiles, stability, as well as heterogeneity and microstructural effects. For each of these features, case studies are provided as RS outcomes for various manufacturing processes that are typically applied to gears and drivetrain components.

They are described in the context of the corresponding challenges posed to the assessment of the RS for each case. Thus, this article acts as a guideline to help drivetrain engineers incorporate RS into both the product design phase and the manufacturing processes throughout the entire supply chain.