Master thesis: Simplified Test-method for Cobalt-free Machining of Gears

The research institute Swerim provides applied research within mining engineering, process metallurgy and materials and manufacturing engineering, mainly for the mining, steel and metals industry. Swerim has 200 co-workers in two locations in Sweden - Luleå and Stockholm.

Overview
Demands of lower emissions and the market growth of electric vehicles require
continuous optimization in the manufacturing of modern high-quality powertrain gears. Improving these processes can however be difficult as they involve specific and expensive machines and tools, only available in production leading to time and resource consuming testing.
 
In this project, a test method will be established where new cutting tool materials and various process optimizations in gear manufacturing can be tested in a more simple and efficient approach with lower waste, higher flexibility and shorter testing times. Testing without advanced machining equipment will allow companies throughout the entire value chain to test their new products.
 
In a second step the methodology will be used to study the influence of Cobalt on the performance of high-speed steel tools. The aim is to reduce the usage of Cobalt in the automotive industry, its negative effects with regards to human right issues and its unpredictable pricing and availability.
 
You will work in a project that attracts great interest by leading actors in Swedish vehicle production. The work will have both practical and theoretical elements, involving tests in the workshops and industry, using advanced instruments for measurements and analysis and traditional metallograhy methods. The project leader is the research institute Swerim. The participating companies are Scania, Erasteel, Ovako, Leax, Ionbond, Sandvik Coromant, Samputensili (Italy) and KTH.
 

Figure: Suggested geometry of test and hobbing tools used for gear manufacturing.

Goal
The diploma work will focus on finding the right parameters in the tests, finding out where Co is essential and where it can be avoided and deliver machining recommendations regarding suitable tool materials and coatings. The results will be confirmed in industry tests with hobbing and skiving.

Further information
Swerim rewards the student with 50 000 SEK for an approved master thesis (30hp).  

Application
Apply by using the application function below. You will receive a confirmation that Swerim has received your application. Please note that we fill the thesis as soon as we find a suitable applicant, which means we can fill the position before the deadline.
The work is planned to start March 2023 at Swerim in Stockholm.

Contact
For further information about project, please contact: 
Håkan Thoors, hakan.thoors@swerim.se

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