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

制造过程一般由材料凝固过程、金属成形过程和一个以上的矫直过程、机械加工和热处理过程组成。加工和最终矫直是必要的，以保证所需的形状和尺寸的机器零件。很少有人尝试在一个以上的生产步骤上优化产品，而且由于世界市场上的单个生产步骤在世界各地的不同国家进行，这一事实产生了困难。冷成型工艺节能、清洁，在生产过程中得到越来越多的应用。另一方面，冷成形会显著改变材料的性能，冷成形的汽车零件需要表面热处理或必须完全硬化以满足强度要求。因此，在一个生产步骤中性能的改进可能会导致下一个，以下一个或最后一个制造步骤中的问题。以这种方式制造的部件显示出广泛的扭曲，必须通过额外昂贵的加工操作来消除。在附加感应淬火的冷拔过程中，变形电位从一个制造步骤到另一个制造步骤的传递将进行实验分析和部分建模。主要影响参数的doe计划（实验设计）将用于确定影响和相关性。减少一个或多个生产操作，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.