Analysis of potentials to improve the machining of hybrid workpieces

Denkena, Berend; Bergmann, Benjamin; Prasanthan, Vannila; Witt, Matthias

doi:10.1007/s11740-018-00870-3

Cited by 9 publications

(4 citation statements)

References 9 publications

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“…The finishing process is carried out by local induction hardening and hardturning, and will be extended by deep rolling, c.f. (Denkena et al, 2019). In order to optimize the finishing process, the production steps and their effect on the bearing service life will be examined more closely.…”

Section: Methodsmentioning

confidence: 99%

Studies on the Influence of Residual Stresses on the Fatigue Life of Rolling Bearings in Dependence on the Production Processes

2020

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The production process significantly influences the surface properties of rolling element bearings raceways. Deep rolling can induce a depth dependent residual stress state. Previous numerical and experimental studies have shown that rolling bearings fatigue life can be positively influenced by high compressive residual stress to a depth of around 300 µm from the surface. By extending the components life, the resource efficiency of machine components can be increased. In order to determine the influence of the residual stress state in bearing fatigue life, a calculation method was developed for predicting the bearing fatigue life. This method was validated for hard-turning and subsequent deep rolling by experiments on a test rig in four-bearing configuration under radial load. An increase of the L 10 bearing life by a factor of 2.5 has been achieved by inducing residual stresses on the bearing's inner ring. Due to similar process control, the manufacturing steps turning and deep rolling were combined. Bearings were manufactured combining the processes hard-turning and deep rolling (called turn-rolling). The heat from the hard machining has an effect on the residual stresses in the bearing subsurface, thus further altering the magnitude and maximum depth of the residual stress influencing the microstructure. With these bearings, the additional fatigue life was determined experimentally and compared to the results of the bearings produced by hard-turning and subsequent deep rolling. It could be shown, that the process of hard turning and subsequent deep rolling has highest potential to achieve improved bearing fatigue life. These findings were transferred to a "Tailored Forming" shaft with integrated raceway in a second step. In this case, a shaft made of mild steel is combined with a cladding layer of high strength bearing steel to be used as a bearing raceway.

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Section: Methodsmentioning

confidence: 99%

Studies on the Influence of Residual Stresses on the Fatigue Life of Rolling Bearings in Dependence on the Production Processes

2020

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“…The tailored forming process chains investigated in CRC 1153 consist of three process areas [16,19]:…”

Section: Background 21 Tailored Formingmentioning

confidence: 99%

“…Finally, the formed blank is machined to the final contour to adjust edge zone as well as surface properties for the part [16,19].…”

Section: Knowledge Modelingmentioning

confidence: 99%

Process Chain-Oriented Design Evaluation of Multi-Material Components by Knowledge-Based Engineering

Herrmann¹,

Plappert²,

Gembarski³

et al. 2023

Algorithms

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The design of components suitable for manufacturing requires the application of knowledge about the manufacturing process chain with which the component is to be manufactured. This article presents an assistance system for decision support in the context of design for manufacturing. The assistance system includes explicit manufacturing process chain knowledge and has an inference engine that can automatically evaluate the manufacturability of a component design based on a given manufacturing process chain and resolve emerging manufacturing conflicts by making adjustments on the component or resource side. A link with a CAD system additionally enables the three-dimensional representation of derived manufacturing stages and manufacturing resources. Within the assistance system, a manufacturing process chain is understood as a configurable design object and is implemented via a constraint satisfaction problem. Furthermore, the required abstraction of manufacturing processes within finite domains can be reduced to the extent that necessary modeling resolution is achieved by incorporating empirical or simulative surrogate models into the CSP. The assistance system was conceptually validated on a tailored forming process chain for the production of a multimaterial shaft and provides added value, as valuable manufacturing information for component designs is automatically derived and made available in explicit form during the component development.

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“…He concluded that even with optimized geometry of the indexable insert tip, both materials have different surface roughnesses if no additional parameter adjustment is made. Denkena et al showed that a material-specific adaptation of the process parameters offers the potential to improve the process quality in terms of surface quality, cutting tool load, machining time and residual stresses [8]. To machine hybrid workpieces material-specifically, the position of the material transition must be known.…”

Section: Introductionmentioning

confidence: 99%

Material identification during turning by neural network

Denkena¹,

Bergmann²,

Handrup³

et al. 2020

Journal of Machine Engineering

Self Cite

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MATERIAL IDENTIFICATION DURING TURNING BY NEURAL NETWORKA design concept for high-performance components involves the combination of different materials in hybrid workpieces. Different material properties and chemical compositions influence the machining quality of hybrid workpieces. To achieve a constant workpiece and process quality, it is necessary to adjust the process parameters to the individual material. Thus, it is mandatory to classify the material during machining for the relevant range of process parameters. This paper examines teaching strategies for neural networks to determine the machined material in process by a small amount of cross points. For this purpose, different training sets are compared. Process parameters with different cutting speeds, feeds and with constant and varying depth of cut are examined. In addition, the signal sources necessary for robust material classification are compared and investigated. The investigation is performed for the cylindrical turning of friction welded EN AW-6082/20MnCr5 shafts. The study shows that an F1 score of 0.99 is achieved at a constant cutting depth, provided that only the corner points of the process window and the machine control signals are used for training. With an additional variation of the cutting depth, the classification rate is significantly improved by the use of external sensors such as the acceleration sensor.

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Analysis of potentials to improve the machining of hybrid workpieces

Cited by 9 publications

References 9 publications

Studies on the Influence of Residual Stresses on the Fatigue Life of Rolling Bearings in Dependence on the Production Processes

Studies on the Influence of Residual Stresses on the Fatigue Life of Rolling Bearings in Dependence on the Production Processes

Process Chain-Oriented Design Evaluation of Multi-Material Components by Knowledge-Based Engineering

Material identification during turning by neural network

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