Abstract
A change in component design could help achieve objectives in lightweight construction. However, lightweight component design can incur serious distortion problems after the final heat treatment due to reduced stiffness or asymmetries in the mass distribution. The analysis of design modification through geometrical variations and their consequences on the distortion behavior through experiments can be costly and time consuming. In this paper, using 3D simulation models, different modified lightweight geometries are simulated. Using these simulation results, the authors try to understand the complex distortion behavior and correlate it with the effects of design modification.
Highlights
The lightweight design and construction of the gears lead to reduced stiffness and asymmetrical mass distribution, which induces serious distortion problems after the final heat treatment
The results achieved here will be the basis for future compensation measures and the optimization of cross-sectional areas of the gear to study their effect on distortion behavior
A detailed description of the experimental investigation can be found in [22] concerning the manufacturing process of the gear, the heat treatment, the distortion measurement by the 3D coordinate measurement machine, the measurement positions, and the determination of the size and shape changes
Summary
Weight reduction has been the prime goal in automobile industries to cater for the needs of economic and ecological aspects. It is of utmost importance to obtain knowledge of the basic mechanisms leading to dimensional and shape changes because of heat treatment to improve the design and reduce the post-processing machining cost and time. This analysis can be pursued either using suitable in situ measurement techniques or using qualified simulation software. The simulation results are validated with those of experimental results, and different distortion criteria are analyzed Using these simulation results, the authors try to understand the complex distortion behavior and correlate it with the effects resulting from design modification. The results achieved here will be the basis for future compensation measures and the optimization of cross-sectional areas of the gear to study their effect on distortion behavior
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