Distortion minimization of disks for gear manufacture
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In this paper, all production steps in the manufacture of disks made of SAE 5120 prior to heat-treatment were analyzed by means of design of experiments (DoE) and the influence of hardenability, pre-heat treatment, forging temperature, and feed rate and partition of material removal in cutting on the distortion of disks were investigated.Abstract:
In order to minimize shape deviations in hardening of gear wheels, all production steps in the manufacture of disks made of SAE 5120 prior to heat-treatment were analyzed by means of design of experiments (DoE). The influence of hardenability, pre-heat treatment, forging temperature, and feed rate and partition of material removal in cutting on the distortion of disks were investigated. Standard case hardening of the disks led to a characteristic shape change called “dishing”. The statistical analysis of the test results has proven that dishing of disks is mainly affected by the partition of the material removal in the considered case. In additional experiments dishing could be eliminated (on average) by an optimized partition of the material removal. However, results from experiments with spray-formed disks and with disks using a different forming strategy imply that the material flow combined with material inhomogeneities are the physical causes for dishing rather than the partition of material removal.read more
Citations
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High pressure gas quenching: Distortion analysis in gears after heat treatment
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References
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Journal ArticleDOI
Residual Stresses — Measurement and Causes in Machining Processes
TL;DR: In this article, the authors investigated the sources of residual stresses generated by machining processes and tried to show how the possible sources for developing residual stresses are involved, and gave a report on the state of the art.
Book
Spray Simulation: Modeling and Numerical Simulation of Sprayforming metals
TL;DR: In this paper, the authors provide an introduction to the various modelling and simulation techniques employed in spray forming, and show how they are applied in process analysis and development, wherever possible, they discuss theoretical results with reference to experimental data.
Journal ArticleDOI
Experimental Study of Distortion Phenomena in Manufacturing Chains
TL;DR: In this paper, the influence and significance of several process parameters in a manufacturing chain of cylindrical bearing rings made of steel SAE 52100 (100Cr6) on the quench hardening distortion were identified using the method of Design of Experiments (DoE) and a statistical analysis of the results.
Journal ArticleDOI
Identification of process parameters affecting distortion of disks for gear manufacture Part I: casting, forming and machining
Brigitte Clausen,F. Frerichs,T. Kohlhoff,Th. Lübben,C. Prinz,R. Rentsch,Jens Sölter,H. Surm,Dirk Stöbener,D. Klein +9 more
TL;DR: In this article, a comprehensive approach to distortion engineering, the entire manufacturing chain from casting to the final heat treatment was considered, and the analysis of the distortion of disks was performed by means of the design of experiments.
Journal ArticleDOI
Spray forming of homogeneous 100Cr6 bearing steel billets
TL;DR: In this article, a heat transfer model of a growing billet was established to investigate the thermal profiles of the billet during spray forming, and an apparent correlation between the cooling and solidification condition of the deposit and its metallurgical properties has been disclosed by means of numerical simulation and experiment.