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

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Abstract

In this investigation, a design of experiments analysis of distortion for a typical manufacturing process involving pre-straightening, cold drawing, and induction hardening of AISI 1045 cylindrical steel bars was carried out. A careful characterization of the material, including residual stress states and geometrical changes, was done for the different manufacturing steps. In order to identify effects and correlations on distortion behavior, the investigated variables included the batch influence, the combined drawing process itself with two different drawing angles and two different polishing and straightening (P.S.) angles, a stress relief treatment which was applied to a part of the samples, and finally induction hardening with two different surface hardening depths. Main and statistically significant effects on the distortion of the induction-hardened samples were found to be in this order: first, the interaction between the drawing angle and batch, then the interaction between drawing angles, and finally drawing angle and induction hardened layer. It was also found that the distortion potentials are transmitted from the drawing process to further manufacturing steps and, consequently, from one production site to the next.

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Abbreviations

AISI:

American Iron and Steel Institute

d 0 :

Interplanar spacing

DoE:

Design of experiments

IH:

Induction hardening

PAG:

Polyalkylene glycol

P.S.:

Polishing and straightening process

r :

Radius

RS:

Residual stress

SR:

Stress relief

XRD:

X-ray diffraction

SHD:

Surface hardening depth

α :

Statistical significance

α 1 :

Semi-die angle in wire drawing process

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Acknowledgments

This work was developed in the frame of the “BRAGECRIM” program (Brazilian German Cooperation Research Initiative in Manufacturing). The authors are deeply indebted to the DFG, CAPES, CNPq, and Finep for financial support and to HZB Berlin (neutron diffraction measurements). Preliminary cooperation also would not have been possible without support from the DAAD and CAPES. The neutron diffraction analysis has been supported by the European Commission under the 7th Framework Program through the Key Action: Strengthening the European Research Area, Research Infrastructures: Contract No. 226507 (NIMI3).

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Authors and Affiliations

  1. Stiftung Institut für Werkstofftechnik, Bremen, Germany

    Thomas Georg Karl Hirsch (Research Director)

  2. Centro de Tecnologia, Universidade Federal do Rio Grande do Sul, Porto Alegre, Brazil

    Alexandre da Silva Rocha (Professor)

  3. LAMEF, Universidade Federal do Rio Grande do Sul, Porto Alegre, Brazil

    Rafael Menezes Nunes (Postdoctoral Researcher)

Authors
  1. Thomas Georg Karl Hirsch
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  2. Alexandre da Silva Rocha
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  3. Rafael Menezes Nunes
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Corresponding author

Correspondence to Rafael Menezes Nunes.

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Manuscript submitted February 15, 2013.

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Hirsch, T.G.K., da Silva Rocha, A. & Menezes Nunes, R. Distortion Analysis in the Manufacturing of Cold-Drawn and Induction-Hardened Components. Metall Mater Trans A 44, 5806–5816 (2013). https://doi.org/10.1007/s11661-013-1952-z

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