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Thyrnau, Germany

Surm H.,IWT - Foundation Institute of Materials Engineering | Hermann M.,ZF Achsgetriebe GmbH | Sattelberger K.,ZF Achsgetriebe GmbH | Kuper A.,ZF Passau GmbH | Hoffmann F.,IWT - Foundation Institute of Materials Engineering
HTM - Haerterei-Technische Mitteilungen | Year: 2011

The Collaborative Research Center Distortion Engineering - Distortion Control in the Production Process interpret distortion as a system property and concentrates on the determination of significant factors and interactions in the overall production process of selected components to identify relevant distortion mechanisms. In a project with the co-operation partner ZF Achsgetriebe GmbH, it was tested if this system oriented approach Distortion Engineering could be transferred to an industrial manufacturing chain.The examined component was a crown wheel made of the steel ZF1. Out of a group of selected parameters along the entire manufacturing chain, the most important factors and interactions concerning distortion were identified in two test plans by means of Design of Experiments (DoE). The alterations of size and shape deviations due to case hardening were dominated by the properties of the forged blanks (heat, pre-heat treatment). Afterwards the factors of the case hardening process (load, agitation and temperature of the oil bath, position of crown wheel in heat treatment batch) influence the distortion. No effect on distortion could be identified from the factors of machining. Based on this experimental work, further examinations were done which were focused on the characterization of the different variants regarding chemical composition and microstructure in dependence of the factors heat and pre-heat treatment. The results were compared with the measured alteration of size and shape deviations to establish a first comprehension of relevant distortion mechanism. © 2012 Carl Hanser Verlag, M+nchen. Source


Surm H.,IWT - Foundation Institute of Materials Engineering | Hermann M.,ZF Achsgetriebe GmbH | Sattelberger K.,ZF Achsgetriebe GmbH | Kuper A.,ZF Passau GmbH | Hoffmann F.,IWT - Foundation Institute of Materials Engineering
HTM - Haerterei-Technische Mitteilungen | Year: 2010

The basic approach to interpret distortion as a system property is more and more accepted in scientific and industrial context. Since 2001, the Collaborative Research Center "Distortion Engineering - Distortion Control in the Production Process" concentrates on the determination of significant factors and interactions in the overall production process of selected components to identify relevant distortion mechanisms. In a maximum term of three years, it will be tested in a project with the co-operation partner ZF Achsgetriebe GmbH if this system-oriented approach "Distortion Engineering" could be transferred to an industrial manufacturing chain. The examined component was a crown wheel made of the steel ZF1 (mod. 17CrNi6-6). The project goal is to reduce significantly the cost-intensive gear grinding at the end of the manufacturing chain by distortion control in the overall production process. To separate the most important factors and interactions concerning distortion out of a group of selected parameters along the entire manufacturing chain, two test plans with a total of 300 crown wheels were realized by means of Design of Experiments (DoE). The results of the extensive coordinate measurements, which are presented in detail in this paper, are the general basis of this identification process. © 2010 Carl Hanser Verlag, München. Source

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