Abstract
In this investigation a DoE (Design of Experiments) analysis of distortion for a typical manufacturing process of pre-straightened, cold drawn and induction hardened AISI 1045 cylindrical steel bars was carried out. A careful characterization of the material, including residual stresses and geometrical changes was done for the different manufacturing steps. The variables included the drawing process itself with two different drawing angles, a stress relief treatment which was applied to one part of the samples and finally an induction heat treatment with two different case depths applied to identify effects and correlations on distortion. Simulation of the drawing process was also used as tool to clarify possibilities and limits of this kind of analysis, depending on the available input data. Different influences on the distortion of the induction hardened samples were found and discussed, as for example the marked dependence of the distortion on drawing angle.
Kurzfassung
Mithilfe einer statistischen Versuchsplanung (DoE, Design of Experiments) wurde der Bauteilverzug von gerichteten, kaltgezogenen und anschließend induktionsgehärteten zylindrischen Drahtabschnitten aus AISI 1045 als typische Prozesskette des Drahtziehens analysiert. Für jeden Prozessschritt erfolgten dabei eine umfangreiche Werkstoffcharakterisierung, eine Untersuchung der Eigenspannungsverteilung sowie eine Ermittlung der Bauteilgeometrie zur Beurteilung der Form- und Maßänderungen. Zur Identifizierung von Einflussfaktoren auf den Verzug wurden Prozessparameter wie Öffnungswinkel des Werkzeuges, optionales Spannungsarmglühen sowie die Härtetiefe beim abschließenden Induktionshärten variiert. Zusätzlich wurden numerische Simulationen des Prozesses durchgeführt, um verschiedene Möglichkeiten der Parametervariation und ihre Grenzen zu ermitteln. Im Rahmen der Untersuchungen konnte der Einfluss unterschiedlicher Parameter, wie die Abhängigkeit des Verzuges vom Öffnungswinkel, identifiziert werden.
References
1. Hoffmann, F.; Kessler, O.; Luebben, Th.; Mayr, P.: Distortion Engineering – Verzugsbeherrschung in der Fertigung. HTM Z. Werkst. Waermebeh. Fertigung57 (2002) 3, p. 213–217Search in Google Scholar
2. Thoben, K. D.; LuebbenTh.; Clausen, B.; Prinz, C.; Schulz, A.: Distortion Engineering: A System Oriented View on the Distortion of Workpieces. Proc. 4th Int. Conf. Quenching and Control of Distortion, 23–24.11.03, Beijing, China; CHTS, Beijing, China, 2003, on CDSearch in Google Scholar
3. Wang, Z.; Gong, B.: Residual Stress in the Forming of Materials. In: Handbook of Residual Stress and Deformation of Steel. ASM Int., Materials Park, USA, 2002, p. 141–149Search in Google Scholar
4. Zoch, H.-W.: From single production step to entire process chain – the global approach of Distortion Engineering. Proc. 2nd Int. Conf. Distortion Engineering IDE 2005, 14–16.09.2005, Bremen, Germany; Zoch, H.-W.; Luebben, Th. (Eds.), p. 3–1010.1002/mawe.200500958Search in Google Scholar
5. Kuboki, T.; Yoshikawa, H.; Neishi, Y.; Kuroda, K.; Akiyama, M.: Influence of back-tension on effect of skin pass in minimizing residual stress levels after cold rod drawing. Ironmaking and Steelmaking28 (2002), p. 117–121Search in Google Scholar
6. Rocha, A. S.; Nunes, R. M.; Hirsch, T.: Changes in the axial residual stresses in AISI 1045 steel bars resulting from a combined drawing process chain. Proc. Inst. Mech. Engineers, Part B: J. Eng. Manuf.226 (2012) B3, p. 459–6510.1177/0954405411422299Search in Google Scholar
7. Standard ASTM E112 – 10: Standard Test Methods for Determining Average Grain Size. In: Book of Standards, Volume: 03.01, ASTM, Materials Park, USA, 2004, p. 26Search in Google Scholar
8. Surm, H.; Kessler, O.; Hoffmann, F.; Mayr, P.: Effect of machining and heating parameters on distortion of AISI 52100 steel bearing rings. Int. J. Mater. Product Technol.24 (2005), p. 55–6210.1504/IJMPT.2005.007954Search in Google Scholar
9. Frerichs, F.; Landek, D.; Luebben, Th.; Hoffmann, F.; Zoch, H.-W.: Prediction of distortion of cylinders without phase transformations. Mat.-wiss. Werkst.37 (2006) 1, p. 63–6810.1002/mawe.200500974Search in Google Scholar
10. Epp, J.; Hirsch, T.: Characterization of the carrier of distortion potential “residual stresses” in the Collaborative Research Centre “Distortion Engineering”. Proc. 3rd Int. Conf. on Distortion Engineering IDE 2011, 14.-16.09.2011 in Bremen, Germany, Zoch, H.-W.; Luebben, Th. (Eds.), p. 351–360Search in Google Scholar
11. Atienza, J. M.; Elices, M.: Influence of residual stresses in the stress relaxation of cold drawn wires. Mater. Struct.37 (2004), p. 301–304Search in Google Scholar
12. Martinez-Peres, M. L.; Mompean, F. J.; Ruiz-Hervias, J.; Borlado, C. R.; Atenzia, J. M.; Garcia-Hernandez, M.; Elices, M.; Gil-Sevillano, J.; Ru LinPeng; Buslaps, T.: Residual stress profiling in the ferrite and cementite phases of cold-drawn steel rods by synchrotron and neutron diffraction. Acta Mater.52 (2004), p. 550310.1016/j.actamat.2004.07.036Search in Google Scholar
13. Acker, K. van; Root, J.; Houte, P. van; Aernoudt, E.: Neutron Diffraction measurement of the residual stress in the cementite and ferrite phases of cold-drawn steel wires. Acta Mater.10 (1996), p. 4039Search in Google Scholar
14. Poeste, T.; Wimpory, R. C.; Schneider, R.: The New and Upgraded Neutron Instruments for Materials Scinece at HMI – Current Activities in Cooperation with Industry. Mat. Sci. Forum524–525 (2006), p. 223–228Search in Google Scholar
15. Wimpory, R. C.; Mikula, P.; Saroun, J.; Poeste, T.; Li, J.; Hoffmann, M.; Schneider, R.: Efficiency boost of the materials science diffractometer E3 at BENSC: One order of magnitude due to a horizontally and vertically focusing monochromator. Neutron News19 (2008) 1, p. 16–1910.1080/10448630701831995Search in Google Scholar
16. Epp, J.; Hirsch, T.; Hunkel, M.; Wimpory, R.: Combined neutron and x-ray diffraction for the characterization of a case hardened disc. Mat. Sci. Forum652 (2010), p. 37–4310.4028/www.scientific.net/MSF.652.37Search in Google Scholar
© 2013, Carl Hanser Verlag, München
