Distortion analysis in a manufacturing process of cold drawn, induction hardened and machined components

制造过程一般包括材料凝固过程、金属成形过程和不止一种矫直过程、机械加工和热处理过程。然后需要进行机械加工和最终校直，以保证机械零件的形状和尺寸符合要求。很少有人尝试在一个以上的生产步骤上优化产品，而困难是因为世界市场中的单一生产步骤发生在世界各地的不同国家。冷成形工艺是一种节能、清洁的工艺，在生产工艺中的应用越来越多。另一方面，冷成形会显著改变材料的性能，冷成形汽车零件需要进行表面热处理或必须完全硬化才能满足强度要求。因此，在一个生产步骤期间性能的改善可能导致在下一步、以下某一步或最终在最后一步制造中出现问题。以这种方式制造的部件显示出很宽的扭曲范围，必须通过额外昂贵的加工操作来消除这些扭曲。在附加感应淬火的冷拔工艺中，将对变形势从一个制造步骤到另一个制造步骤的传输进行实验分析和部分建模。将使用主要影响参数的能源部计划(试验设计)来确定影响和相关性。预计将减少一个或多个制造操作，例如额外的矫直和/或加工。

Manufacturing processes in general consist of materials solidification processes, metal forming processes and more than one straightening process, machining and heat treatment processes. Machining and final straightening is then necessary to guarantee the required shape and dimensions of machine parts. Few attempts are made to optimize products over more than one production step and difficulties arise from the fact that single production steps in a wortd market take place in different countries around the wortd. Cold forming processes are energy efficient and clean and are used in production processes with an increasing number. Cold forming on the other side significanlly changes materials properties and cold formed automotive parts need a surface heat treatment or have to be through hardened completely to fulfill strength requirements. An improvement of properties during one production step consequently can result in problems in the next, one of the following or finally in the last manufacturing step. Components manufactured in this way show a broad band of distortions, which have to be removed by additional expensive machining operations. The transmission of distortion potentials from one manufacturing step to the other in a cold drawing process with additional induction hardening will be analyzed experimentally and partially modeled. A DoE-plan (design of experiments) of main affecting parameters will be used to identify effects and correlations. A reduction of one or more manufacturing operation as e.g. additional straightening and/or machining will be expected.