Abstract
The process‐chain of highly stressed parts incorporates among others casting, forming, and heat treatment. Segregations are always found within these parts. Segregations and its consequences are only understandable by considering the whole process‐chain. In this paper, segregations within the hot rolled bar and after cold forging to bevel gears are analyzed metallographically. Dilatometer specimens are used for analyzing the phase transformation behavior from different segregation structures within the hot rolled bar. The deformation during forming and the influence on the microstructure after heat treatment is discussed. A coupled forming‐heat treatment simulation is presented based on the experimental findings. The deformation of the macro‐segregation is calculated by a forming simulation. A phase transformation model depending on the macro‐segregation is used for calculation of the microstructure after heat treatment. The final microstructure and hardness distribution of formed parts is calculated and discussed in comparison with the experimental results.
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