Gears are essential components in power transmission systems. The replacement of the transmission of a wind turbine can reach more than $300000 and face long lead times. Previous studies have shown that Laser-Directed Energy Deposition (L-DED) has the potential to be used in the repair of gears. However, there is a lack of understanding of the appropriate tool-path planning strategies and their impact on the performance of the gears repaired by L-DED. In this work, we study several strategies for the repair of cylindrical (straight and helical) gears. The strategies consider several types of gear tooth failures, allowing for the repair of a portion of the tooth and the reconstruction of the whole tooth. The studied strategies encompass planar and non-planar slicing procedures. We manufactured several gear teeth to demonstrate the geometrical and kinematic feasibility of some strategies. We performed destructive analyses on the manufactured teeth to check for manufacturing faults and measure their hardness. We used AISI 316L for these experiments, although we are assessing and testing powdered materials for their potential use in gear repair using L-DED. We are also working on the evaluation of the mechanical performance (e.g., wear resistance, bending fatigue) of the teeth manufactured with L-DED.
Keywords
- Additive Manufacturing
- Directed Energy Deposition
- Gear Repair
- Path Planning