Browsing by Author "Hunkel,M."
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Conference Object Citation Count: 2FEM modeling of the distortion of blank/case hardened gear blanks due to chemical banding(2012) Şimşir, Caner; Hunkel,M.; Lütjens,J.; Rentsch,R.; Manufacturing EngineeringIn this study, a FEM process-chain simulation model is presented for the prediction of distortion of blank and case-hardened SAE 5120 (EN 20MnCr5) steel gear blanks. For this purpose, the evolution of the banded microstructure stemming from the continuous casting process was traced by computer simulations of subsequent shape rolling, forging and machining steps. The calculated flow-net was imported into the in-house heat treatment simulation module empowered with the recently developed "Anisotropic Transformation Strain (ATS)" model which enables the inclusion of the effect of banded microstructure on distortion. Then, both blank and case-hardening processes were simulated and verified experimentally. The results indicate good predictions of the dishing directions and dishing-free cutting strategy in both cases; the dishing magnitude is predicted well in blank-hardening simulations while the quality of the prediction is reasonable in case-hardening. Copyright © 2012 ASM International® All rights reserved.Conference Object Citation Count: 10The prediction of the distortion of blank-hardened gear blanks by considering the effect of prior manufacturing operations(2011) Şimşir, Caner; Eisbrecher,I.; Hunkel,M.; Lübben,T.; Hoffmann,F.; Manufacturing EngineeringThis article presents a recently developed mathematical model for Integration of the effects of prior manufacturing steps into heat treatment simulations by considering the modification of the banded microstructure in forming and machining processes. The model was justified by simulating the heating, austenitizatlon and quenching of dilatometer specimens machined from the forged discs with distinct orientations to the banded microstructure. Then, It Is tested In prediction of dishing of blank-hardened gear blanks, which cannot be reproduced by previously available models. The model provides promising results for process chain simulation and development of system-oriented measures for the solution of heat treatment distortion problem. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.