Details
| Original language | English |
|---|---|
| Pages (from-to) | 2409-2417 |
| Number of pages | 9 |
| Journal | International Journal of Advanced Manufacturing Technology |
| Volume | 108 |
| Issue number | 7-8 |
| Publication status | Published - 9 Jun 2020 |
Abstract
To manufacture semi-finished hybrid workpieces with tailored properties, a finite element simulation assisted process chain design was investigated. This includes the process steps of cross wedge rolling, hot geometry inspection, induction hardening, and fatigue testing. The process chain allows the utilisation of material combinations such as high-strength steels with low-cost and easy to process steels. Here, plasma transferred arc welding is applied to supply the process chain with hybrid specimen featuring different steel grades. An overview of the numerical approaches to consider the various physical phenomena in each of the process steps is presented. The properties of the component behaviour were investigated via the finite element method (FEM) and theoretical approaches. At first, the manufacturing of a hybrid workpiece featuring a near net shape geometry with improved mechanical properties due to recrystallising the weld was computed, using the example of a cross wedge rolling process. The rolling process was designed by means of FEM to determine suitable process parameters and to reduce experimental testing. An optical multi-scale geometry inspection of the hot workpiece is meant to be carried out after each manufacturing step to detect potential undesired forming or cooling-induced deformations. Due to the heat transfer from the hot component to the ambient medium, an optical measurement is affected by the developing inhomogeneous refractive index field in air. To gain a basic understanding of the refractive index field and induced light deflection effects, computations were conducted using heat transfer and ray tracing simulations. According to the proposed process route, a subsequent local heat treatment of the hybrid component is required to adapt the mechanical properties by a spray cooling assisted induction hardening. The heat treatment step was computed via a 2D FEM calculation. After finishing by machining, the hybrid material shafts are examined in fatigue tests under load conditions. To predict the component’s lifetime under rolling contact fatigue, a damage accumulation model was combined with an FE simulation. The resulting residual stress state after quenching and the geometry after the finishing process were used as input data for the fatigue life calculations.
Keywords
- Bearing fatigue life, Cross wedge rolling, Induction heating, Optical geometry measurement, Process simulation, Tailored forming
ASJC Scopus subject areas
- Engineering(all)
- Control and Systems Engineering
- Computer Science(all)
- Software
- Engineering(all)
- Mechanical Engineering
- Computer Science(all)
- Computer Science Applications
- Engineering(all)
- Industrial and Manufacturing Engineering
Cite this
- Standard
- Harvard
- Apa
- Vancouver
- BibTeX
- RIS
In: International Journal of Advanced Manufacturing Technology, Vol. 108, No. 7-8, 09.06.2020, p. 2409-2417.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Simulation assisted process chain design for the manufacturing of bulk hybrid shafts with tailored properties
AU - Coors, Timm
AU - Pape, Florian
AU - Kruse, Jens
AU - Blohm, Thoms
AU - Beermann, Rüdiger
AU - Quentin, Lorenz
AU - Herbst, Sebastian
AU - Langner, Jan
AU - Stonis, Malte
AU - Kästner, Markus
AU - Reithmeier, Eduard
AU - Nürnberger, Florian
AU - Poll, Gerhard
N1 - Funding information: The authors thank the German Research Foundation (DFG) for the financial and organisational support of this project.
PY - 2020/6/9
Y1 - 2020/6/9
N2 - To manufacture semi-finished hybrid workpieces with tailored properties, a finite element simulation assisted process chain design was investigated. This includes the process steps of cross wedge rolling, hot geometry inspection, induction hardening, and fatigue testing. The process chain allows the utilisation of material combinations such as high-strength steels with low-cost and easy to process steels. Here, plasma transferred arc welding is applied to supply the process chain with hybrid specimen featuring different steel grades. An overview of the numerical approaches to consider the various physical phenomena in each of the process steps is presented. The properties of the component behaviour were investigated via the finite element method (FEM) and theoretical approaches. At first, the manufacturing of a hybrid workpiece featuring a near net shape geometry with improved mechanical properties due to recrystallising the weld was computed, using the example of a cross wedge rolling process. The rolling process was designed by means of FEM to determine suitable process parameters and to reduce experimental testing. An optical multi-scale geometry inspection of the hot workpiece is meant to be carried out after each manufacturing step to detect potential undesired forming or cooling-induced deformations. Due to the heat transfer from the hot component to the ambient medium, an optical measurement is affected by the developing inhomogeneous refractive index field in air. To gain a basic understanding of the refractive index field and induced light deflection effects, computations were conducted using heat transfer and ray tracing simulations. According to the proposed process route, a subsequent local heat treatment of the hybrid component is required to adapt the mechanical properties by a spray cooling assisted induction hardening. The heat treatment step was computed via a 2D FEM calculation. After finishing by machining, the hybrid material shafts are examined in fatigue tests under load conditions. To predict the component’s lifetime under rolling contact fatigue, a damage accumulation model was combined with an FE simulation. The resulting residual stress state after quenching and the geometry after the finishing process were used as input data for the fatigue life calculations.
AB - To manufacture semi-finished hybrid workpieces with tailored properties, a finite element simulation assisted process chain design was investigated. This includes the process steps of cross wedge rolling, hot geometry inspection, induction hardening, and fatigue testing. The process chain allows the utilisation of material combinations such as high-strength steels with low-cost and easy to process steels. Here, plasma transferred arc welding is applied to supply the process chain with hybrid specimen featuring different steel grades. An overview of the numerical approaches to consider the various physical phenomena in each of the process steps is presented. The properties of the component behaviour were investigated via the finite element method (FEM) and theoretical approaches. At first, the manufacturing of a hybrid workpiece featuring a near net shape geometry with improved mechanical properties due to recrystallising the weld was computed, using the example of a cross wedge rolling process. The rolling process was designed by means of FEM to determine suitable process parameters and to reduce experimental testing. An optical multi-scale geometry inspection of the hot workpiece is meant to be carried out after each manufacturing step to detect potential undesired forming or cooling-induced deformations. Due to the heat transfer from the hot component to the ambient medium, an optical measurement is affected by the developing inhomogeneous refractive index field in air. To gain a basic understanding of the refractive index field and induced light deflection effects, computations were conducted using heat transfer and ray tracing simulations. According to the proposed process route, a subsequent local heat treatment of the hybrid component is required to adapt the mechanical properties by a spray cooling assisted induction hardening. The heat treatment step was computed via a 2D FEM calculation. After finishing by machining, the hybrid material shafts are examined in fatigue tests under load conditions. To predict the component’s lifetime under rolling contact fatigue, a damage accumulation model was combined with an FE simulation. The resulting residual stress state after quenching and the geometry after the finishing process were used as input data for the fatigue life calculations.
KW - Bearing fatigue life
KW - Cross wedge rolling
KW - Induction heating
KW - Optical geometry measurement
KW - Process simulation
KW - Tailored forming
UR - http://www.scopus.com/inward/record.url?scp=85086158692&partnerID=8YFLogxK
U2 - 10.1007/s00170-020-05532-2
DO - 10.1007/s00170-020-05532-2
M3 - Article
AN - SCOPUS:85086158692
VL - 108
SP - 2409
EP - 2417
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
SN - 0268-3768
IS - 7-8
ER -