Development of Process Signatures for Manufacturing Processes with Thermal Loads without and with hardening

Abstract

The presented investigation focuses on the correlation between concrete physical quantities and resulting modifications. The idea is that not the different manufacturing processes itself produce the modifications but the generated physical and chemical loads. The correlation between the generated loads and the modifications is called Process Signature. Every process has its own Process signature, which are than directly comparable to Process signatures of different Processes. If the loads of different Process signatures are equal, the modifications should be equal, too. This contribution presents the development of Process Signatures for grinding and induction-heating with and without hardening. Based on Finite Element simulations and experimental work the external thermal loading of both processes were characterized by the resulting temperature development, which correlates with the change of the residual stress state. To provide a comparable simulation approach, moving heat source theory in combination with energetic quantities were applied. The investigations show that surface grinding and induction-heating are interchangeable for certain parameter regimes regarding the changes of the residual stress state. Mainly temperature gradients and thermal diffusion are responsible for the considered modifications. The comparison of heating without hardening and processes with hardening delivers an additional insight into the thermal processes and can help to understand and distinguish the different working mechanisms within the processes.