Abstract
In automotive industry, heat treatment of components is implicitly related to distortion. This phenomenon is particularly obvious in the case of gearbox parts because of their typical geometry and precise requirements. Even if distortion can be anticipated to an extent by experience, it remains complex to comprehend. Scientific literature and industrial experience show that the whole manufacturing process chain has an influence on final heat treatment distortions. This paper presents an approach to estimate the influence of some factors on the distortion, based on the idea of a distortion potential taking into account not only geometry but also the manufacturing process history. Then the idea is developed through experiments on an industrial manufacturing process to understand the impact of residual stress due to machining on shaft bending and teeth distortion during heat treatment. Instead of being measured, residual stress is being neutralized. By comparing lots between each other, connections between gear teeth geometry and manufacturing steps before heat treatment are obtained. As a consequence, geometrical nonconformities roots can be determined more easily thanks to this diagnosis tool, and corrective actions can be applied. Secondly, the influence of product geometry on bending is experimentally considered. Moreover, metallurgical observations enable to explain the influence of workpieces geometry on shaft bending. Thanks to the obtained results, process and product recommendations to decrease shafts bending are proposed.
Similar content being viewed by others
References
Kohlhoff T, Prinz C, Rentsch R, Surm H (2011) Influence of manufacturing parameters on gear distortion. Proc. of the 3rd international conference on distortion engineering 2011, Bremen, 14th to 16th September, pp 155–165
Cook W T (1999) A review of selected steel-related factors controlling distortion in heat-treatable steels. Heat Treat Met 26:27–36
Clausen B, Frerichs F, Kohlhoff T, Lübben T, Prinz C, Rentsch R, Sölter J, Surm H, Stöbener D, Klein D (2009) Identification of process parameters affecting distortion of disks for gear manufacture part I: casting, forming and machining. Materialwiss Werkst 40(5,6):354–360
Hoffmann F, Keßler O, Lübben T, Mayr P (2002) “Distortion Engineering” Verzugsbeherrschung in der Fertigung. HTM 57(3):213–217
Zoch H W (2009) Distortion engineering: vision or ready to application. Materialwiss Werkst 40(5,6):342–348
Cho J R, Kang W J, Kim M G, Lee J H, Lee Y S, Bae W B (2004) Distortions induced by heat treatment of automotive bevel gears. J Mater Process Technol 153:476–481
Kohlhoff T (2009) Analysis of the forces in different regions during hobbing and their effect on distortion. Materialwiss Werkst 40:390–395
Husson R, Dantan J Y, Baudouin C, Silvani S, Scheer T, Bigot R (2012) Evaluation of process causes and influences of residual stress on gear distortion. Ann CIRP 61(1):551–554
Sugimoto T, Watanabe Y (2004) Evaluation of important factors affecting quench distortion of carburized hypoid gear with shaft by using computer simulation methods. Cailiao Rechuli Xuebao/Trans Mater Heat Treat 25(5):480–485
Husson R (2013) Contribution a l’identification des origines des deformations revelees au traitement thermique. Application a l’analyse d’une gamme de fabrication d’arbres a dentures de boites de vitesses. Arts et Metiers ParisTech, PhD thesis
Goch G (2003) Gear metrology. Ann CIRP 52(2):659–695
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Husson, R., Baudouin, C., Bigot, R. et al. Consideration of residual stress and geometry during heat treatment to decrease shaft bending. Int J Adv Manuf Technol 72, 1455–1463 (2014). https://doi.org/10.1007/s00170-014-5688-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-5688-8