Advancements in Additive Manufacturing for Gear Cutting Tools: Design, Prototyping, and Testing

The industry of gear cutting tools is, in general, characterized by small batches, long manufacturing times and high costs, dealing with tailor-made and high value-added tools. In this context, additive manufacturing finds a vast potential of bringing disruptiveness and efficiency increase. This study presents developments regarding the application of the technology for manufacturing gear cutting tools. The design for additive manufacturing (DfAM) and the manufacture of HSS steel prototypes through Laser Powder Bed Fusion (L-PBF) and Laser Direct Energy Deposition (L-DED) are the highlighted topics, along with the corresponding potentials and challenges for additive manufacturing in this kind of application. The geometric complexity of a shaping tool and use of HSS steels leads to challenges related to the emergence of cracks along the deposition. Geometry opportunities such different construction material for body and tool are approached for productivity and economical gains. A lighter design with a better optimization of the thermal exchange was obtained through the creation of regions for the circulation of the cutting fluid. Issues are also raised for the implementation of such solutions. The additively manufactured shaping tool was tested in a real industrial environment. The performance of the tool was measured based on the evolution of the flank wear. In conclusion, additive manufacturing can be a key-technology for gear cutting tools in the future, bringing a disruptive path of new opportunities.