Cost- and energy-efficient manufacture of gears by laser beam melting

This paper suggests two integrated models for cost and life cycle assessment in a cradle-to-gate framework focussing an industrial process sequence. Gear wheel manufacturing in a low volume or high variant production scale is chosen as a production scenario. Three industrial process sequences for gear production based on machining, hobbing, and LBM are investigated. Special focus is set to the impact of lightweight design on energy- and cost-efficiency of the manufacturing sequence. The key factors influencing cost- and energy-intensity are identified recommending a production scenario that is worthwhile for LBM for the small scale production of gears. It is concluded that both cost- and energy-efficiency have to be assessed with different process alternatives in order to identify a worthwhile scenario for LBM based on cost and life cycle assessment models. Lightweight design is identified as the most significant factor for reducing costs and energy-consumption that suggests employing lightweight design for cost- and energy-efficiency. The intended audience of this contribution are scientists, industrial applicants of LBM and conventional gear manufacturers.