Abstract
In order to withstand high mechanical and tribological loads, it is important that the components not only have a high core ductility but also a hard surface. Typically, a suitable microstructure is created by heat treatment processes before the workpiece is machined. However, these processes are time and energy consuming and can lead to component distortion. It would therefore be of great advantage if no additional heat treatment process would be required to produce a hardened subsurface zone. Since turning is often already integrated as a machining process in production lines, it would be advantageous to create a hardened subsurface within this process. As there is no possibility to measure the hardness directly during the turning process, a soft sensor was developed to determine the properties of the subsurface directly during the machining process. Steels with metastable austenite are of particular interest in this context, as metastable austenite can be converted into martensite by deformation. The amount of martensite produced in the subsurface can be adjusted provided that suitable turning parameters can be found. For this purpose, a process parallel material removal simulation was used to determine the actual conditions governing the process. It was found that there is a correlation between the martensite content and the amplitude of the 3rd harmonic of eddy current testing. Therefore, an eddy current sensor accompanying the process can be used as a basis for controlling the turning process for tailored martensite volume content adjustment.
Zusammenfassung
Um hohen mechanischen und tribologischen Belastungen standhalten zu können, ist es wichtig, dass die Bauteile nicht nur eine hohe Kernduktilität, sondern auch eine harte Oberfläche aufweisen. Typischerweise wird eine geeignete Mikrostruktur durch Wärmebehandlungsprozesse erzeugt, bevor das Werkstück bearbeitet wird. Diese Prozesse sind jedoch zeit- und energieaufwändig und können zu Bauteilverzug führen. Daher wäre es von großem Vorteil, wenn kein zusätzlicher Wärmebehandlungsprozess erforderlich wäre, um eine gehärtete Randzone zu erzeugen. Da das Drehen bereits häufig als Bearbeitungsprozess in Fertigungslinien integriert ist, wäre es vorteilhaft, innerhalb dieses Prozesses eine gehärtete Randzone zu erzeugen. Noch gibt es keine Möglichkeit die Härte während des Drehprozesses direkt zu messen. Deswegen wurde ein Soft-Sensor entwickelt, um die Eigenschaften der Randzone direkt während der Bearbeitung zu bestimmen. Dafür sind Stähle mit metastabilem Austenit besonders geeignet, da metastabiler Austenit durch Verformung in Martensit umgewandelt werden kann und die Menge des in der Randzone erzeugten Martensits durch die richtige Wahl der Drehparameter eingestellt werden kann. Dazu wurden mit einer prozessparallelen Materialabtragssimulation die tatsächlichen Eingriffsbedingungen im Prozess ermittelt und überprüft. Des Weiteren wurde eine Korrelation zwischen dem Martensitgehalt und der Amplitude der 3. Harmonischen der Wirbelstromprüfung festgestellt. Daher kann ein prozessbegleitender Wirbelstromsensor als Grundlage für die Steuerung des Drehprozesses zur gezielten Einstellung des Martensitvolumengehaltes verwendet werden.
Funding source: Deutsche Forschungsgemeinschaft
Award Identifier / Grant number: 401800578
Funding statement: Financial support of this study by the German Research Foundation (DFG) within the research priority program SPP 2086 (grant project number 401800578) is gratefully acknowledged.
About the authors
M. Sc. Lara Vivian Fricke, born in 1993, studied material engineering at the RWTH Aachen and since 2018 has been working as a scientific employee at the institute of Material Science at the Leibniz Universität Hannover.
M. Sc. Hai Nam Nguyen, born in 1992, studied industrial engineering at the Leibniz University of Hannover and since 2017 has been working as a scientific employee at the institute of Production Engineering and Machine Tools at the Leibniz Universität Hannover.
Apl. Prof. Dr. rer. nat. habil. Bernd Breidenstein, born 1957, after studying at the universities of Marburg, Göttingen and Clausthal and earning a doctorate, worked in various industrial companies. Since 2001 he has been head of surface and subsurface analysis at the Institute of Production Engineering and Machine Tools.
Prof. Dr.-Ing. Berend Denkena is Head of the Institute of Production Engineering and Machine Tools at the Leibniz Universität Hannover. After obtaining doctorate at the Faculty of Mechanical Engineering at the Leibniz Universität Hannover in 1992, he worked as a design engineer and Head of various research groups for Thyssen Production Systems both in Germany and the United States. From 1996 to 2001 he was Head of Engineering and Turning Machine Development at Gildemeister Drehmaschinen in Bielefeld. Since 2001 he has been a full professor of Production Engineering and Machine Tools and director of the Institute of Production Engineering and Machine Tools at the Leibniz Universität Hannover. He is a CIRP Fellow Member. His primary areas of research are geometry and functionalizing manufacturing processes, machine tools for cutting and grinding, production planning and control, and simulation of manufacturing processes.
Dr.-Ing. Marc-André Dittrich studied industrial engineering at the Leibniz Universität Hannover and since 2012 has been working as a scientific employee at the institute of Production Engineering and Machine Tools (IFW) at the Leibniz Universität Hannover. In the period from 2014 to 2015 he was responsible for the management of the department Functionalization at the IFW. Since 2015 he is head of the department Production Systems.
Prof. Dr.-Ing. Hans Jürgen Maier, born in 1960, studied material science in Erlangen. He received his doctorate in 1990 with a thesis on the influence of ambient media on the fatigue behaviour of steels. After completing his doctorate, he became head of the electron microscopy working group and moved to the University of Siegen as senior research engineer in 1993. In 1998 he received the Masing Memorial Prize of the DGM and after a research stay in the USA he was appointed to the chair of materials science at the University of Paderborn in 1999. Since October 2012 he is head of the Institute of Material Science at the Leibniz Universität Hannover. The focus of his research is the investigation of the microstructure-property correlation and the development of validated models that allow the prediction of the behaviour of highly stressed materials under practical conditions. The results of his research have been published in more than 500 scientific papers. Furthermore, he is a member of the editorial board of several international journals. Since 2018 he is a full member of the German Academy of Science and Engineering (acatech) and the Berlin-Brandenburg Academy of Sciences and Humanities.
Dr.-Ing. David Zaremba studied mechanical engineering at the Leibniz Universität Hannover. Following his studies, he completed his doctorate under the direction of Prof. Maier on the repair of fibre-reinforced plastics. Since 2017, he is head of the division “non-destructive testing methods” at the Institute of Materials Science. The focus of his research is the investigation of microstructural changes in combination with the change of magnetic material properties during and after production processes, and, based on this, property-oriented process control.
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