The manufacturing method of the composite worm gear housing using the cold injection

In the work the innovation manufacturing method of the composite worm gear housing of the electric power steering system was presented. Modification of the worm gear housing of the electric power steering system consisted in changing the material from which it will be manufactured. Until now, gear housings were made of aluminum by hot injection method. The present works aim at using the pDCPD material and the cold injection method into manufacturing the new generation of the worm gear housing. The planned change was aimed at eliminating the machining process of the cast aluminum body and reducing its mass. In the work was assumed, that the assembled worm gear housing, with all cooperating elements, will be manufactured using the cold injection method. As a result of the manufacturing process the finished product in the worm gear form of the electric power steering system will be obtained. In addition, the geometrical form and the dimensions system of the support elements were determined in relation to the assembled worm and the worm wheel together with the bearing system. The presented method allows eliminating the expensive and time-consuming process of machining of the molding gear housing.