How Timken Steel Technology Enhances Your Gear Design

How Timken. Steel Technology Enhances Your Gear Design, Performance and Manufacturing AGMA Solutions Center Gear EXPO, Oct. 20 th, 2015 E. Buddy Damm, Ph. D, Chief Engineer, Industrial Steel Solutions

Outline Timken. Steel Corporation at a Glance Tailored Steel Products and Services • • • Long products capabilities Differentiated steel making processes Value added products and services New 20, 000 Sq. Ft. Technology Center • • State of the art cleanness characterization Virtual Gear Life Modeling

Timken. Steel Corporation We help customers push the bounds of what’s possible by creating steel products and services to overcome their toughest challenges In 2014, over 25% of the steel we produced was supplied to the gear industry • • • Innovative team of experts driving custom and tailored solutions Institutional expertise developed over 100 years Deep technical knowledge of processes and applications ~30% of our product offerings are less than 5 years old A 100 -year old start-up

Broadest Size Range: SBQ Steel Long Products and Services in North America Vertical Caster: 11” x 17” (279 mm x 432 mm) 18” x 24” (457 mm x 610 mm) or 11” x 17” 4

Investing To Serve The Gear Industry Jumbo Bloom Vertical Caster 5 • • • Improved inclusion floatation Improved segregation for heat treat response Can cast difficult grades 18 x 24”, or 11 x 17” cast section size Improved solidification pattern In-Line Forge Press • Sound centers up to 16” rounds • UT Inspection to Class A, B

Value Add Services - St. Clair Plant § Opened in 1993 § Located in Eaton, OH, USA Capabilities: § § Transmission ring gears, CV joint cages, radial forming, drilling, broaching, grinding, honing, CNC Targeted investments for green machining and precision component manufacturing

Investing to serve the automotive gear industry Supply chain investments of over $30 M for ready-to-finish gear preforms Conversion of high-quality Timken. Steel bar and tubes into preforms to serve finish gear manufacturing OEMs Investments in cutting, green machining, advance preform manufacturing Consistent chemistry, clean steel, manufacturability (broaching), heat treatment and distortion response

Advanced Steel Technology Failure Analysis Advanced Modeling Advanced Product & Process Engineering Development Labs Microscopy UT Cleanness Analysis Broach Life Test Cell ASPEX Cleanness Analysis Failure Analysis Gleeble Dual Beam SEM/FIB Modeling Software

What is Clean Steel? All steels contain some concentration of non-metallic impurities (inclusions) Inclusions are of various types (compositions), sizes and shapes Sulfide Nitride Oxide Stringer Clean Steel contains a minimal number of harmful inclusions 10

Inclusion Initiated Gear Failure OKAY, Got it… How big of an inclusion can my gear suffer and still perform?

Stress Intensity s Stress intensity (KI) is a function of the maximum principle tensile stress and the flaw geometry area. For a circular flaw the diameter to square root area ratio is close to 1 (0. 88) s

Linear Elastic Fracture Mechanics 10, 000 Hrs 12, 000 Hrs 3, 000 Hrs 100 Hrs No Crack Growth Log-Log Linear Crack Growth Unstable Crack Growth

Critical Flaw Size for Fatigue Initiation

Aspex Multiple Sample Holder / Scan Set Up polished steel samples loaded in holder - scan fields (~200 mm 2) 15

SEM Automatic Image Analysis Results

Comparative Histogram of Oxide Size 17

Timken. Steel Vs. Remelt

Virtual Component Fatigue Model

Micro-Inclusion Parametric Study – Hertzian Contact Loading • • • Determine the effect of micro-inclusion parameters on max stress and fatigue index Parameters: Micro-inclusion Size Aspect Ratio Depth (Z-position) • Proximity • Orientation (within simulation volume) • Orientation (inclusion-to-inclusion) • Number of inclusions in close proximity

Inclusion Proximity – 3 Inclusions • Max stress vs. proximity of 3 spherical oxide inclusions (20 um diameter) 3 stress levels: No interactions – max stress level for single inclusion 1308 MPa Fatigue Index = 1. 52 • 2 Inclusions interacting 1555 MPa Fatigue Index = 3. 03 • 3 Inclusions interacting 1950 MPa Fatigue Index = 17. 7 Increasing Rolling Reduction

Monte Carlo Simulation Results Normalized Fatigue Life Experimental Life Test Data (normalized) VCFM - 250 mm Diameter VCFM - 100 mm Diameter 1 0. 01 0. 0001 0. 1 Stringer Length / Volume (um/mm^3) 1 10

VIRTUAL COMPONENT FATIGUE MODEL Perform calculations in a small volume 23 Use external specialized software to generate stress fields and inputs for rapid Virtual calculations

Summary At Timken. Steel we have 100 years of experience in making clean steels for optimal fatigue performance Our Jumbo Bloom Vertical Caster offers game changing large bar quality and value Our Forge Press provides large bar with sound centers to optimize your performance Our team, our tools and our facilities are uniquely capable and uniquely positioned to enhance your gear performance, design and manufacturing

Come See Us! Booth 1745

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