Improve your surface quality of gears in electric vehicles

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Optimisation of gear surfaces

By improving the surface quality of gears, a significant increase in performance can be achieved in electrically driven vehicles.

A smoother surface with a higher contact ratio can increase the efficiency of torque transmission and thus the achievable range of the vehicle. The maximum surface pressure can also be further increased in order to be able to transmit higher torques of the electric motors and to take account of the lightweight design concept through smaller gears.

KAPP NILES offers various solutions here, from fine or polish grinding as a combined process to polish grinding as a single process, and thus the right technology for your requirements.

60 % improvement in roughness with
innovative KAPP NILES grinding technology

You can meet these requirements for the highest surface qualities economically and reproducibly with fine or polishing grinding on KAPP NILES machines. Combined tools with different specifications are used for this purpose.

Conventional generating grinding

Conventional generating grinding uses a ceramic-bonded corundum grinding worm that consists of one specification throughout.

Combined process fine grinding

Fine grinding uses a combined tool with two specifications. In addition to the conventional grinding area, the tool has a fine grinding area that differs in terms of the tool specification. This allows surface finishes of Rz = 1 - 2.5 µm to be achieved with process reliability.

Combined process polish grinding

For even higher requirements, conventional grinding is combined with polish grinding. For this process, a tool with two areas is used. For polish grinding, a tool area with an elastic polyurethane or synthetic resin bond is used. Surface qualities of Rz < 1 µm can be achieved.

Polish grinding

After hardening, gears are conventionally ground to remove the existing allowance including hardening distortions and to produce the final workpiece geometry. The tooth flanks are then shot-peened to harden the surface. In the final work step, they are polish-ground with a one-piece polyurethane-bonded tool as a single technology to achieve a high surface quality.

AGMA Emerging Technology Webinar
"Generating Ultrafine Surface Finishes on Gear Teeth for EV Applications"

Patrick Duhre, Team Leader Test Grinding / Contract Grinding at KAPP NILES, will present more on the topic of "Generating Ultrafine Surface Finishes on Gear Teeth for EV Applications":

  • Overview on superfinishing technologies on a gear grinding machine.
  • Classification of the technologies into different process chains.
  • Process and machine requirements for different tool geometries

Optimise your gear solutions for e-drives

At KAPP NILES, you not only get the technology, but also the flexibility to adapt to a wide range of e-mobility requirements. Contact us to learn more about our advanced solutions. We will be pleased to show you how to increase your manufacturing potential in the field of e-mobility with KAPP NILES. Trust in Technology with KAPP NILES!

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