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Bending Distortion Analysis of a Steel Shaft Manufacturing Chain from Cold Drawing to Grinding

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Abstract

Shafts are usually manufactured from bars that are cold drawn, cut machined, induction hardened, straightened, and finally ground. The main distortion is characterized by bending that appears after induction hardening and is corrected by straightening and/or grinding. In this work, the consequence of the variation of manufacturing parameters on the distortion was analyzed for a complete manufacturing route for production of induction hardened shafts made of Grade 1045 steel. A DoE plan was implemented varying the drawing angle, cutting method, induction hardening layer depth, and grinding penetration depth. The distortion was determined by calculating curvature vectors from dimensional analysis by 3D coordinate measurements. Optical microscopy, microhardness testing, residual stress analysis, and FEM process simulation were used to evaluate and understand effects of the main carriers of distortion potential. The drawing process was identified as the most significant influence on the final distortion of the shafts.

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Acknowledgments

The authors would like to thank the funding agencies CAPES and CNPq from Brazil and DFG from Germany for the financial support for this work within the framework of the BRAGECRIM program and the HZB Berlin for the neutron measurements.

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Authors and Affiliations

  1. Metal Forming Laboratory, Federal University of Rio Grande do Sul, Av. Bento Gonçalves, 9500, CEP 91501-970, Porto Alegre, Brazil

    Vinicius Waechter Dias & Juliana Zottis

  2. PPGEM, Metal Forming Laboratory, Federal University of Rio Grande do Sul, Porto Alegre, Brazil

    Alexandre da Silva Rocha

  3. Division of Materials Science, Foundation Institute for Materials Science, Badgasteiner Str. 3, 28359, Bremen, Germany

    Juan Dong, Jérémy Epp & Hans Werner Zoch

Authors
  1. Vinicius Waechter Dias
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  2. Alexandre da Silva Rocha
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  3. Juliana Zottis
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  4. Juan Dong
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  5. Jérémy Epp
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  6. Hans Werner Zoch
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Corresponding author

Correspondence to Vinicius Waechter Dias.

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Manuscript submitted August 8, 2016.

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Dias, V.W., da Silva Rocha, A., Zottis, J. et al. Bending Distortion Analysis of a Steel Shaft Manufacturing Chain from Cold Drawing to Grinding. Metall Mater Trans A 48, 1893–1902 (2017). https://doi.org/10.1007/s11661-016-3948-y

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  • DOI: https://doi.org/10.1007/s11661-016-3948-y

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