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Kohlhoff T.,Foundation Institute of Material Science IWT | Solter J.,Foundation Institute of Material Science IWT | Brinksmeier E.,Foundation Institute of Material Science IWT
Production Engineering | Year: 2012

This study presents investigations on the fundamental mechanisms of part distortion during the machining of disks (cylindrical gear base bodies). The work focuses on the effects of machining induced residual stresses and inhomogeneous material removal. In this context the workpiece clamping was investigated as a major impact factor on the distortion. In order to analyze and describe the complex shape deviations, an appropriate distortion characterization method was developed. Since the distortion of disks directly affects the gear wheel quality, the results will help to understand the formation of gear distortion as well as to reduce and compensate it. © 2011 The Author(s).

Kolkwitz B.,Foundation Institute of Material Science IWT | Foeckerer T.,TU Munich | Heinzel C.,Foundation Institute of Material Science IWT | Zaeh M.f.,TU Munich | Brinksmeier E.,Foundation Institute of Material Science IWT
Procedia Engineering | Year: 2011

Besides conventional heat treatment operations, an innovative approach for surface hardening is the grind-hardening process. During this process the dissipated heat from grinding is used for a martensitic phase transformation in the subsurface region of machined components. Additionally, compressive residual stresses are induced in the grindhardened surface layer. However, for the implementation of grind-hardening into industrial production extensive experimental tests are required to achieve iterative results of hardening depth. This paper focuses on the identification of parameter sets for a sufficient grind-hardening in outer-diameter grinding. On the one hand, grinding tests were conducted supported by metallographic investigations; on the other hand, a finite-element-based model was used to predict the surface integrity resulting from grind-hardening. © 2012 Published by Elsevier Ltd.

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