Distortion Analysis in the Manufacturing of Cold-Drawn and Induction-Hardened Components

Hirsch, T.; Rocha, Alexandre da Silva; Nunes, Rafael Menezes

doi:10.1007/s11661-013-1952-z

Cited by 7 publications

(13 citation statements)

References 19 publications

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“…The shaft geometry (notches) takes the third place, followed by the interaction of the drawing, cutting method, and induction hardening. The results confirmed the finding in previous studies [21,22] and in agreement with other research works [5,20,23] regarding distortion of cold-formed components.…”

Section: Discussionsupporting

confidence: 93%

Investigation of the Influence Factors on Distortion in Induction-Hardened Steel Shafts Manufactured from Cold-Drawn Rod

Dong¹,

Épp²,

Rocha

et al. 2015

Metall Mater Trans A

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In this study, the distortion of steel shafts was investigated before and after induction hardening. Several essential influencing factors in the manufacturing process chain regarding cold drawing, cutting method, notches on the shafts, and induction hardening were analyzed by design of experiment (DoE). Further necessary examinations of microstructures, hardness profile, segregation of chemical composition, and residual stress state were conducted for understanding the distortion behavior. The results of the statistical analysis of the DoE showed that the drawing process is the most important factor influencing distortion. The surface hardening depth of induction hardening is the second main factor. The relationship between inhomogeneities in the work pieces and the distortion was finally discussed.

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Section: Discussionsupporting

confidence: 93%

Investigation of the Influence Factors on Distortion in Induction-Hardened Steel Shafts Manufactured from Cold-Drawn Rod

Dong¹,

Épp²,

Rocha

et al. 2015

Metall Mater Trans A

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“…In fact, some previous works have shown that the surface residual stresses will be more compressive in the surface using a P.S. angle of 16 ° [1,17].…”

Section: Resultsmentioning

confidence: 99%

“…After pre-straightening macro residual stresses are compressive (-166 MPa) at the measured position of 0 ° (see Figure 2). From X-Ray diffraction analysis of straightened bars ahead of the drawing it is already known that phase stresses in ferrite vary in axial direction as well as in circumferential direction due to the horizontal and vertical straightening [17]. After the calculation micro residual stresses in ferrite values of -63 MPa are present and those of +873 MPa in the cementite.…”

Section: Resultsmentioning

confidence: 99%

“…At the same time, the convex roll is responsible for a final polishing of the bar, and is responsible to a localized plastic deformation in the surface with a penetration of less than 1 pct, this plastic deformation causes the surface elongation. The nature of residual stresses introduced by plastic deformation strongly depends upon the shape of the deformation zone [17,22], due to this, it is obvious that the residual stress nature and magnitude in P.S. process will be closely dependent on the convex roll.…”

Section: Resultsmentioning

confidence: 99%

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Residual stress states in cementite and ferrite in a combined cold drawing process of AISI 1045 steel using neutron diffraction and synchrotron radiation

Nunes¹,

Rocha²,

Hirsch³

2021

Tecnol. Metal. Mater. Min.

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The evaluation and control of residual stress states in manufacturing processes such as cold drawing can be difficult, especially in multi-phase materials. Diffraction methods are ideal for characterizing residual stresses in individual phases provided these phases scatter neutrons or X-rays well enough to obtain a good signal. Residual stresses determination problems in drawn components have been reported. Main constraints are measurements in the primary ferrite phase only. The presence of cementite in carbon steel is often neglected. A problem that has not yet been extensively investigated is how residual stresses in the ferrite and cementite phases develop in subsequent steps of material processing such as cold drawing. In this work a combined straightening and bar drawing process of AISI 1045 round bars from coils of a hot-rolled material was investigated. A careful characterization of the material, including residual stress states in the ferrite (α−Fe) and cementite (Fe 3 C) phases, using neutron diffraction and synchrotron diffraction was performed for each of the different manufacturing steps. The drawing and polishing and straightening (P.S.) parameters by crossed rolls were changed to evaluate their influence on the α−Fe and Fe 3 C residual stress distributions. After the drawing process, residual stresses in the cementite phase are highly tensile, as already reported, however it can be shown that after polishing and straightening steps residual stresses in the cementite phase decrease and residual stress distributions also depend on the tool angle used.

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“…In more recent studies, induction heating was performed to enhance the fatigue strength of AISI E52100 bearing steel [28]. Experiment analyses are also applied to study distortion of cold-drawn and induction-hardened components [29]. Jeong et al [30] tried to predict the deformation of curve shape steel plates in high-frequency induction heating.…”

Section: Introductionmentioning

confidence: 99%

A novel investigation into the edge effect reduction of 4340 steel disc through induction hardening process using magnetic flux concentrators

Parvinzadeh

Karganroudi

Omidi

et al. 2021

Int J Adv Manuf Technol

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Induction hardening serves as one of the best mass production processes used recently due to its ability to quickly generating high-intensity heat in a well-de ned location of the part. Numerous advantages of this method make it a reliable technique to produce a thin martensite layer on the part surface that has compressive residual stresses. In this regard, the presented study is devoted to investigating utilizing induction heating for surface hardening of AISI 4340 steel disc. The purpose is to evaluate the performance of magnetic ux concentrators and the effects of the induction process parameter on the case-depth and edge effect in the surface hardening of the disc. Once the proper range of parameters is de ned, Taguchi experimentation planning is used to frame comprehensive experimentation with the minimum possible trial. Then, the case-depth of discs is evaluated on their cross-sections (edge and middle plane) through hardness pro le measurement of samples using a micro-indentation hardness machine. The results are then statistically analyzed using Analysis of Variance (ANOVA) and Response Surface Methodology (RSM) to determine the best combination of parameters to achieve maximum casedepth yet minimum edge effect. The goodness-of-t regression models are then developed to predict the case-depth pro le as a function of machine parameters based on linear regression utilizing case-depth responses in the edge and middle plane of discs. Results imply that maximum case-depth with minimum edge effect can be produced by using the highest heating time along with the average amplitude of the power, axial gap, and radial gap. This study gives a good exploration of case-depths optimized by setting up process parameters when magnetic ux concentrator is utilized, thus, a guideline to reduce discs edge effect in induction surface hardening application is given.

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Distortion Analysis in the Manufacturing of Cold-Drawn and Induction-Hardened Components

Cited by 7 publications

References 19 publications

Investigation of the Influence Factors on Distortion in Induction-Hardened Steel Shafts Manufactured from Cold-Drawn Rod

Investigation of the Influence Factors on Distortion in Induction-Hardened Steel Shafts Manufactured from Cold-Drawn Rod

Residual stress states in cementite and ferrite in a combined cold drawing process of AISI 1045 steel using neutron diffraction and synchrotron radiation

A novel investigation into the edge effect reduction of 4340 steel disc through induction hardening process using magnetic flux concentrators

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