Efficiency and Roughness Characteristics of Surface Treated Powder Metal Electric Vehicle Gears

Abstract: This thesis presents an experimental research study aimed at identifying the optimal mechano-chemical surface treatment for powder metallurgy gears utilized in electric vehicles (EVs). The primary objective of the study is to determine the most effective surface treatment method in terms of enhancing gear transmission efficiency. The experiments utilise a specialized FZG test rig, which allows for comprehensive testing under realistic operating conditions. In addition, a surface roughness measurement device is used to evaluate the impact of the surface treatments on the gear's surface characteristics. The results obtained from the experiments reveal a particular type of surface treatment as the most effective among the test samples considered within the scope of the thesis, as it significantly improves gear transmission efficiency. These findings contribute to the advancement of surface treatment techniques for powder metallurgy gears used in EVs, aiding in the development of more efficient and high-performing gear systems for electric mobility.