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Jens Sölter - One of the best experts on this subject based on the ideXlab platform.
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Influence of the turning process on the distortion of disks for Gear Manufacture
Production Engineering, 2011Co-Authors: Tim Kohlhoff, Jens Sölter, Ekkard BrinksmeierAbstract:This study presents investigations on the fundamental mechanisms of part distortion during the machining of disks (cylindrical Gear base bodies). The work focuses on the effects of machining induced residual stresses and inhomogeneous material removal. In this context the workpiece clamping was investigated as a major impact factor on the distortion. In order to analyze and describe the complex shape deviations, an appropriate distortion characterization method was developed. Since the distortion of disks directly affects the Gear wheel quality, the results will help to understand the formation of Gear distortion as well as to reduce and compensate it.
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Distortion minimization of disks for Gear Manufacture
International Journal of Machine Tools & Manufacture, 2011Co-Authors: Ekkard Brinksmeier, R. Rentsch, T. Lübben, Udo Fritsching, Jens SölterAbstract: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.
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identification of process parameters affecting distortion of disks for Gear Manufacture part ii heating carburizing quenching
Materialwissenschaft Und Werkstofftechnik, 2009Co-Authors: B Clausen, R. Rentsch, Tim Kohlhoff, Jens Sölter, T. Lübben, F Frerichs, C Prinz, H Surm, Dirk Stobener, D KleinAbstract:In this work the applied approach to ‘Distortion Engineering’ is based on the consideration of the entire manufacturing chain of disks, from casting to the final heat treatment, made from the steel grade 20MnCr5 (SAE 5120). Part II presents the results of the investigations concerning the final heat treatment parameters on the distortion of the disks, whereas part I describes the effect of the influence parameters from casting to cutting. The disk geometry was selected, in order to reduce the expected complexity of influence parameters in Gear wheel distortion. The parameter identification took place by means of the design of experiments (DoE). Volume flow rate of quenching gas, hardening temperature and carburizing depth have the expected effect on the volume change of the disks. In addition, occurring differences in the size changes of the inner and the outer surfaces were detected. For the shape changes it was found, that the choice of the loading tool shows the main influence. Furthermore a change in the loading tool does clearly affect the dishing behavior of the disks. Whereas, a relevant influence of the carburizing depth on the shape changes of disks could not be identified in this investigation. As a conclusion from the results presented in part I and II it is assumed that the identified parameters of disk distortion also effect the distortion of Gear wheels. Identifikation von Prozessparametern, die den Verzug von Zahnradrohlingen (Scheiben) beeinflussen Teil 2: Erwarmen, Aufkohlen, Abschrecken In dieser Arbeit ist die Methodik des „Distortion Engineering” auf die gesamte Prozesskette von Scheiben aus dem Material 20MnCr5, von der Stahlerzeugung bis zur abschliesenden Warmebehandlung, angewendet worden. Teil II prasentiert die Ergebnisse der Untersuchungen der Einflussgrosen der abschliesenden Warmebehandlung auf den Scheibenverzug. Die Einflussgrosen von der Stahlerzeugung bis zum Zerspanen wurden in Teil I vorgestellt. Die Scheibengeometrie wurde ausgewahlt, um die zu erwartende Komplexitat von Einflussgrosen auf den Zahnradverzug zu reduzieren. Die Identifizierung der Einflussgrosen wurde mittels der Methode „Design of Experiments” (DoE) durchgefuhrt. Stromungsgeschwindigkeit des Abschreckgases, Hartetemperatur und Aufholungstiefe zeigen den erwarteten Effekt auf die Volumenanderung der Scheiben. Zusatzlich wurden Unterschiede in den Masanderungen der inneren und auseren Mantelflache erkannt. Bei den Formanderungen wurde herausgefunden, dass die Wahl der Auflage den grosten Einfluss besas. Ein relevanter Einfluss der Aufkohlungstiefe auf die Formanderungen von Scheiben konnte bei dieser Untersuchung nicht festgestellt werden. Als Schlussfolgerung der prasentierten Ergebnisse von Teil I und II kann vermutet werden, dass die identifizierten Einflussgrosen des Scheibenverzugs auch den Zahnradverzug beeinflussen.
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identification of process parameters affecting distortion of disks for Gear Manufacture part i casting forming and machining
Materialwissenschaft Und Werkstofftechnik, 2009Co-Authors: B Clausen, R. Rentsch, Tim Kohlhoff, Jens Sölter, T. Lübben, F Frerichs, C Prinz, H Surm, Dirk Stobener, D KleinAbstract:Towards determining the influence parameters on the distortion of Gear wheels made from the steel grade 20MnCr5 (SAE 5120), in this work the analysis of the distortion of disks is presented. The parameter identification was performed by means of the design of experiments (DoE). According to a comprehensive approach to distortion engineering, the entire manufacturing chain was considered from casting to the final heat treatment. Due to the complexity of this manufacturing chain the investigation was divided into two parts, the processes before the final heat treatment and the final heat treatment process itself. Here, in part I, the results of the investigation of the processes before the final heat treatment are discussed while in part II the results of the final heat treatment are presented. Releasing the accumulated distortion potential of the influence parameters of the processes from casting to cutting by a standard case hardening led to characteristic size changes of the disks. For the shape changes the cutting strategy showed a high influence on the change of dishing. Assuming that the cutting strategy can continuously be varied there should be a strategy for which no change of the dishing occurs, which would provide the means for compensation of distortion.
Ekkard Brinksmeier - One of the best experts on this subject based on the ideXlab platform.
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Influence of the turning process on the distortion of disks for Gear Manufacture
Production Engineering, 2011Co-Authors: Tim Kohlhoff, Jens Sölter, Ekkard BrinksmeierAbstract:This study presents investigations on the fundamental mechanisms of part distortion during the machining of disks (cylindrical Gear base bodies). The work focuses on the effects of machining induced residual stresses and inhomogeneous material removal. In this context the workpiece clamping was investigated as a major impact factor on the distortion. In order to analyze and describe the complex shape deviations, an appropriate distortion characterization method was developed. Since the distortion of disks directly affects the Gear wheel quality, the results will help to understand the formation of Gear distortion as well as to reduce and compensate it.
-
Distortion minimization of disks for Gear Manufacture
International Journal of Machine Tools & Manufacture, 2011Co-Authors: Ekkard Brinksmeier, R. Rentsch, T. Lübben, Udo Fritsching, Jens SölterAbstract: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.
T. Lübben - One of the best experts on this subject based on the ideXlab platform.
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Distortion minimization of disks for Gear Manufacture
International Journal of Machine Tools & Manufacture, 2011Co-Authors: Ekkard Brinksmeier, R. Rentsch, T. Lübben, Udo Fritsching, Jens SölterAbstract: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.
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identification of process parameters affecting distortion of disks for Gear Manufacture part ii heating carburizing quenching
Materialwissenschaft Und Werkstofftechnik, 2009Co-Authors: B Clausen, R. Rentsch, Tim Kohlhoff, Jens Sölter, T. Lübben, F Frerichs, C Prinz, H Surm, Dirk Stobener, D KleinAbstract:In this work the applied approach to ‘Distortion Engineering’ is based on the consideration of the entire manufacturing chain of disks, from casting to the final heat treatment, made from the steel grade 20MnCr5 (SAE 5120). Part II presents the results of the investigations concerning the final heat treatment parameters on the distortion of the disks, whereas part I describes the effect of the influence parameters from casting to cutting. The disk geometry was selected, in order to reduce the expected complexity of influence parameters in Gear wheel distortion. The parameter identification took place by means of the design of experiments (DoE). Volume flow rate of quenching gas, hardening temperature and carburizing depth have the expected effect on the volume change of the disks. In addition, occurring differences in the size changes of the inner and the outer surfaces were detected. For the shape changes it was found, that the choice of the loading tool shows the main influence. Furthermore a change in the loading tool does clearly affect the dishing behavior of the disks. Whereas, a relevant influence of the carburizing depth on the shape changes of disks could not be identified in this investigation. As a conclusion from the results presented in part I and II it is assumed that the identified parameters of disk distortion also effect the distortion of Gear wheels. Identifikation von Prozessparametern, die den Verzug von Zahnradrohlingen (Scheiben) beeinflussen Teil 2: Erwarmen, Aufkohlen, Abschrecken In dieser Arbeit ist die Methodik des „Distortion Engineering” auf die gesamte Prozesskette von Scheiben aus dem Material 20MnCr5, von der Stahlerzeugung bis zur abschliesenden Warmebehandlung, angewendet worden. Teil II prasentiert die Ergebnisse der Untersuchungen der Einflussgrosen der abschliesenden Warmebehandlung auf den Scheibenverzug. Die Einflussgrosen von der Stahlerzeugung bis zum Zerspanen wurden in Teil I vorgestellt. Die Scheibengeometrie wurde ausgewahlt, um die zu erwartende Komplexitat von Einflussgrosen auf den Zahnradverzug zu reduzieren. Die Identifizierung der Einflussgrosen wurde mittels der Methode „Design of Experiments” (DoE) durchgefuhrt. Stromungsgeschwindigkeit des Abschreckgases, Hartetemperatur und Aufholungstiefe zeigen den erwarteten Effekt auf die Volumenanderung der Scheiben. Zusatzlich wurden Unterschiede in den Masanderungen der inneren und auseren Mantelflache erkannt. Bei den Formanderungen wurde herausgefunden, dass die Wahl der Auflage den grosten Einfluss besas. Ein relevanter Einfluss der Aufkohlungstiefe auf die Formanderungen von Scheiben konnte bei dieser Untersuchung nicht festgestellt werden. Als Schlussfolgerung der prasentierten Ergebnisse von Teil I und II kann vermutet werden, dass die identifizierten Einflussgrosen des Scheibenverzugs auch den Zahnradverzug beeinflussen.
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identification of process parameters affecting distortion of disks for Gear Manufacture part i casting forming and machining
Materialwissenschaft Und Werkstofftechnik, 2009Co-Authors: B Clausen, R. Rentsch, Tim Kohlhoff, Jens Sölter, T. Lübben, F Frerichs, C Prinz, H Surm, Dirk Stobener, D KleinAbstract:Towards determining the influence parameters on the distortion of Gear wheels made from the steel grade 20MnCr5 (SAE 5120), in this work the analysis of the distortion of disks is presented. The parameter identification was performed by means of the design of experiments (DoE). According to a comprehensive approach to distortion engineering, the entire manufacturing chain was considered from casting to the final heat treatment. Due to the complexity of this manufacturing chain the investigation was divided into two parts, the processes before the final heat treatment and the final heat treatment process itself. Here, in part I, the results of the investigation of the processes before the final heat treatment are discussed while in part II the results of the final heat treatment are presented. Releasing the accumulated distortion potential of the influence parameters of the processes from casting to cutting by a standard case hardening led to characteristic size changes of the disks. For the shape changes the cutting strategy showed a high influence on the change of dishing. Assuming that the cutting strategy can continuously be varied there should be a strategy for which no change of the dishing occurs, which would provide the means for compensation of distortion.
R. Rentsch - One of the best experts on this subject based on the ideXlab platform.
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Distortion minimization of disks for Gear Manufacture
International Journal of Machine Tools & Manufacture, 2011Co-Authors: Ekkard Brinksmeier, R. Rentsch, T. Lübben, Udo Fritsching, Jens SölterAbstract: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.
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identification of process parameters affecting distortion of disks for Gear Manufacture part ii heating carburizing quenching
Materialwissenschaft Und Werkstofftechnik, 2009Co-Authors: B Clausen, R. Rentsch, Tim Kohlhoff, Jens Sölter, T. Lübben, F Frerichs, C Prinz, H Surm, Dirk Stobener, D KleinAbstract:In this work the applied approach to ‘Distortion Engineering’ is based on the consideration of the entire manufacturing chain of disks, from casting to the final heat treatment, made from the steel grade 20MnCr5 (SAE 5120). Part II presents the results of the investigations concerning the final heat treatment parameters on the distortion of the disks, whereas part I describes the effect of the influence parameters from casting to cutting. The disk geometry was selected, in order to reduce the expected complexity of influence parameters in Gear wheel distortion. The parameter identification took place by means of the design of experiments (DoE). Volume flow rate of quenching gas, hardening temperature and carburizing depth have the expected effect on the volume change of the disks. In addition, occurring differences in the size changes of the inner and the outer surfaces were detected. For the shape changes it was found, that the choice of the loading tool shows the main influence. Furthermore a change in the loading tool does clearly affect the dishing behavior of the disks. Whereas, a relevant influence of the carburizing depth on the shape changes of disks could not be identified in this investigation. As a conclusion from the results presented in part I and II it is assumed that the identified parameters of disk distortion also effect the distortion of Gear wheels. Identifikation von Prozessparametern, die den Verzug von Zahnradrohlingen (Scheiben) beeinflussen Teil 2: Erwarmen, Aufkohlen, Abschrecken In dieser Arbeit ist die Methodik des „Distortion Engineering” auf die gesamte Prozesskette von Scheiben aus dem Material 20MnCr5, von der Stahlerzeugung bis zur abschliesenden Warmebehandlung, angewendet worden. Teil II prasentiert die Ergebnisse der Untersuchungen der Einflussgrosen der abschliesenden Warmebehandlung auf den Scheibenverzug. Die Einflussgrosen von der Stahlerzeugung bis zum Zerspanen wurden in Teil I vorgestellt. Die Scheibengeometrie wurde ausgewahlt, um die zu erwartende Komplexitat von Einflussgrosen auf den Zahnradverzug zu reduzieren. Die Identifizierung der Einflussgrosen wurde mittels der Methode „Design of Experiments” (DoE) durchgefuhrt. Stromungsgeschwindigkeit des Abschreckgases, Hartetemperatur und Aufholungstiefe zeigen den erwarteten Effekt auf die Volumenanderung der Scheiben. Zusatzlich wurden Unterschiede in den Masanderungen der inneren und auseren Mantelflache erkannt. Bei den Formanderungen wurde herausgefunden, dass die Wahl der Auflage den grosten Einfluss besas. Ein relevanter Einfluss der Aufkohlungstiefe auf die Formanderungen von Scheiben konnte bei dieser Untersuchung nicht festgestellt werden. Als Schlussfolgerung der prasentierten Ergebnisse von Teil I und II kann vermutet werden, dass die identifizierten Einflussgrosen des Scheibenverzugs auch den Zahnradverzug beeinflussen.
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identification of process parameters affecting distortion of disks for Gear Manufacture part i casting forming and machining
Materialwissenschaft Und Werkstofftechnik, 2009Co-Authors: B Clausen, R. Rentsch, Tim Kohlhoff, Jens Sölter, T. Lübben, F Frerichs, C Prinz, H Surm, Dirk Stobener, D KleinAbstract:Towards determining the influence parameters on the distortion of Gear wheels made from the steel grade 20MnCr5 (SAE 5120), in this work the analysis of the distortion of disks is presented. The parameter identification was performed by means of the design of experiments (DoE). According to a comprehensive approach to distortion engineering, the entire manufacturing chain was considered from casting to the final heat treatment. Due to the complexity of this manufacturing chain the investigation was divided into two parts, the processes before the final heat treatment and the final heat treatment process itself. Here, in part I, the results of the investigation of the processes before the final heat treatment are discussed while in part II the results of the final heat treatment are presented. Releasing the accumulated distortion potential of the influence parameters of the processes from casting to cutting by a standard case hardening led to characteristic size changes of the disks. For the shape changes the cutting strategy showed a high influence on the change of dishing. Assuming that the cutting strategy can continuously be varied there should be a strategy for which no change of the dishing occurs, which would provide the means for compensation of distortion.
Tim Kohlhoff - One of the best experts on this subject based on the ideXlab platform.
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Influence of the turning process on the distortion of disks for Gear Manufacture
Production Engineering, 2011Co-Authors: Tim Kohlhoff, Jens Sölter, Ekkard BrinksmeierAbstract:This study presents investigations on the fundamental mechanisms of part distortion during the machining of disks (cylindrical Gear base bodies). The work focuses on the effects of machining induced residual stresses and inhomogeneous material removal. In this context the workpiece clamping was investigated as a major impact factor on the distortion. In order to analyze and describe the complex shape deviations, an appropriate distortion characterization method was developed. Since the distortion of disks directly affects the Gear wheel quality, the results will help to understand the formation of Gear distortion as well as to reduce and compensate it.
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identification of process parameters affecting distortion of disks for Gear Manufacture part ii heating carburizing quenching
Materialwissenschaft Und Werkstofftechnik, 2009Co-Authors: B Clausen, R. Rentsch, Tim Kohlhoff, Jens Sölter, T. Lübben, F Frerichs, C Prinz, H Surm, Dirk Stobener, D KleinAbstract:In this work the applied approach to ‘Distortion Engineering’ is based on the consideration of the entire manufacturing chain of disks, from casting to the final heat treatment, made from the steel grade 20MnCr5 (SAE 5120). Part II presents the results of the investigations concerning the final heat treatment parameters on the distortion of the disks, whereas part I describes the effect of the influence parameters from casting to cutting. The disk geometry was selected, in order to reduce the expected complexity of influence parameters in Gear wheel distortion. The parameter identification took place by means of the design of experiments (DoE). Volume flow rate of quenching gas, hardening temperature and carburizing depth have the expected effect on the volume change of the disks. In addition, occurring differences in the size changes of the inner and the outer surfaces were detected. For the shape changes it was found, that the choice of the loading tool shows the main influence. Furthermore a change in the loading tool does clearly affect the dishing behavior of the disks. Whereas, a relevant influence of the carburizing depth on the shape changes of disks could not be identified in this investigation. As a conclusion from the results presented in part I and II it is assumed that the identified parameters of disk distortion also effect the distortion of Gear wheels. Identifikation von Prozessparametern, die den Verzug von Zahnradrohlingen (Scheiben) beeinflussen Teil 2: Erwarmen, Aufkohlen, Abschrecken In dieser Arbeit ist die Methodik des „Distortion Engineering” auf die gesamte Prozesskette von Scheiben aus dem Material 20MnCr5, von der Stahlerzeugung bis zur abschliesenden Warmebehandlung, angewendet worden. Teil II prasentiert die Ergebnisse der Untersuchungen der Einflussgrosen der abschliesenden Warmebehandlung auf den Scheibenverzug. Die Einflussgrosen von der Stahlerzeugung bis zum Zerspanen wurden in Teil I vorgestellt. Die Scheibengeometrie wurde ausgewahlt, um die zu erwartende Komplexitat von Einflussgrosen auf den Zahnradverzug zu reduzieren. Die Identifizierung der Einflussgrosen wurde mittels der Methode „Design of Experiments” (DoE) durchgefuhrt. Stromungsgeschwindigkeit des Abschreckgases, Hartetemperatur und Aufholungstiefe zeigen den erwarteten Effekt auf die Volumenanderung der Scheiben. Zusatzlich wurden Unterschiede in den Masanderungen der inneren und auseren Mantelflache erkannt. Bei den Formanderungen wurde herausgefunden, dass die Wahl der Auflage den grosten Einfluss besas. Ein relevanter Einfluss der Aufkohlungstiefe auf die Formanderungen von Scheiben konnte bei dieser Untersuchung nicht festgestellt werden. Als Schlussfolgerung der prasentierten Ergebnisse von Teil I und II kann vermutet werden, dass die identifizierten Einflussgrosen des Scheibenverzugs auch den Zahnradverzug beeinflussen.
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identification of process parameters affecting distortion of disks for Gear Manufacture part i casting forming and machining
Materialwissenschaft Und Werkstofftechnik, 2009Co-Authors: B Clausen, R. Rentsch, Tim Kohlhoff, Jens Sölter, T. Lübben, F Frerichs, C Prinz, H Surm, Dirk Stobener, D KleinAbstract:Towards determining the influence parameters on the distortion of Gear wheels made from the steel grade 20MnCr5 (SAE 5120), in this work the analysis of the distortion of disks is presented. The parameter identification was performed by means of the design of experiments (DoE). According to a comprehensive approach to distortion engineering, the entire manufacturing chain was considered from casting to the final heat treatment. Due to the complexity of this manufacturing chain the investigation was divided into two parts, the processes before the final heat treatment and the final heat treatment process itself. Here, in part I, the results of the investigation of the processes before the final heat treatment are discussed while in part II the results of the final heat treatment are presented. Releasing the accumulated distortion potential of the influence parameters of the processes from casting to cutting by a standard case hardening led to characteristic size changes of the disks. For the shape changes the cutting strategy showed a high influence on the change of dishing. Assuming that the cutting strategy can continuously be varied there should be a strategy for which no change of the dishing occurs, which would provide the means for compensation of distortion.
