| Article ID | Journal | Published Year | Pages | File Type |
|---|---|---|---|---|
| 1701557 | Procedia CIRP | 2012 | 6 Pages |
Distortion considerably influences manufacturing costs, especially if thin-walled parts are machined. To ensure a flexible economical machining, novel processes have to be developed to control distortion within the process chain. Then, reworking by straightening during quenching or by costly hard processing can be kept to a minimum. The fundamental concept of ‘Distortion Engineering’ is based on the inverse application of identified distortion potential to compensate geometric deviations. In the case of thin-walled bearing rings the distortion is related to both, deviation of the wall thickness and the shape. These deviations originate mainly from an inhomogeneous material removal and uneven residual stress state in the workpieces subsurface caused by deformations due to clamping forces during the soft-turning. An adapted non-circular finishing cut can counteract the distortion. Previous work showed that the adaption of depth of cut depending on assessed geometric irregularities reduces deviations by at least two-third compared to non-compensated cutting. Compensation to zero deviation needs a deeper understanding; hence disturbances during the compensation cuts are investigated within this paper. An uneven change of subsurface residual stress state has a retro-active effect on the workpieces’ shape. Experimental results illustrate that the mechanical process loads are alternating with oscillation of the depth of cut. However, only an impact of adapted cutting on residual stresses perpendicular to the cutting direction (axial stresses) was detected. So far, it can be concluded that adapted cutting not leads to an unexpected change of out-of-roundness during subsequent heat treatment. Additionally, the results revealed that the compensation potential is highly affected by a change of workpieces’ deformation due to material removal during one longitudinal cut.
