Simulation assisted process chain design for the manufacturing of bulk hybrid shafts with tailored properties

verfasst von

Timm Coors, Florian Pape, Jens Kruse, Thoms Blohm, Rüdiger Beermann, Lorenz Quentin, Sebastian Herbst, Jan Langner, Malte Stonis, Markus Kästner, Eduard Reithmeier, Florian Nürnberger, Gerhard Poll

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.

Organisationseinheit(en)

Institut für Maschinenkonstruktion und Tribologie
Institut für Mess- und Regelungstechnik
Institut für Werkstoffkunde

Externe Organisation(en)

Institut für integrierte Produktion Hannover (IPH) gGmbH

Typ

Artikel

Journal

International Journal of Advanced Manufacturing Technology

Band

108

Seiten

2409-2417

Anzahl der Seiten

9

ISSN

0268-3768

Publikationsdatum

09.06.2020

Publikationsstatus

Veröffentlicht

Peer-reviewed

Ja

ASJC Scopus Sachgebiete

Steuerungs- und Systemtechnik, Software, Maschinenbau, Angewandte Informatik, Wirtschaftsingenieurwesen und Fertigungstechnik

Elektronische Version(en)

https://doi.org/10.1007/s00170-020-05532-2 (Zugang: Offen)