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August 14, 2013
Abstract
In this investigation a DoE (Design of Experiments) analysis of distortion for a typical manufacturing process of pre-straightened, cold drawn and induction hardened AISI 1045 cylindrical steel bars was carried out. A careful characterization of the material, including residual stresses and geometrical changes was done for the different manufacturing steps. The variables included the drawing process itself with two different drawing angles, a stress relief treatment which was applied to one part of the samples and finally an induction heat treatment with two different case depths applied to identify effects and correlations on distortion. Simulation of the drawing process was also used as tool to clarify possibilities and limits of this kind of analysis, depending on the available input data. Different influences on the distortion of the induction hardened samples were found and discussed, as for example the marked dependence of the distortion on drawing angle.
