Evaluation of Geometrical Parameters of a Spur Gear Manufactured in an Incremental Process from GP1 Steel

The main applicability criterion of an additive process is whether it allows a functional component to be directly manufactured. Obtaining the assumed dimensional and shape accuracy is an aspect of such functionality. In the case of additive manufacturing, geometrical accuracy depends on the additive technique, the use of which requires additional processes. This study presents the application of coordinate measurement methods to determine geometry reproduction accuracy for gears made in a hybrid process. The authors were able to determine the accuracy of gear geometry reproduction by means of Additive Manufacturing (AM) DMLS (Direct Metal Laser Sintering) techniques supplemented by subtractive finishing. Deformation for test models manufactured using the additive method were evaluated, along with the effect of post-processing, especially in terms of geometric deviations and the presence of shrinkage affecting the amount of allowance required in the correct subtractive manufacturing process. Model geometry was verified by contactless optical system ATOS II Triple Scan and a specialist coordinate measuring machine P40 by Klingelnberg. The analyses revealed that the machining allowance of 0.4 mm in the test model made it possible to obtain gear accuracy class 8 (in line with the assumptions) according to DIN 3962 when tooth spaces were machined using a non-specialist tool.