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Analysis of process parameters during press quenching of bevel gear parts
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Computer Systems for Design and Manufacturing.
2012 (English)In: The 5th International Swedish Production Symposium: 6th-8th of November 2012 Linköping, Sweden / [ed] Mats Björkman, 2012, 251-259 p.Conference paper, Published paper (Refereed)
Abstract [en]

Defining manufacturing tolerances is an important task for a process planner before starting production of a new product or introducing new processes. One of the more complex processes to handle is the heat treatment of gears. Press quenching is a heat treatment method where the gear is mechanically forced to keep or attain the desired geometry, with less geometrical distortions in comparison to oil bath quenching. The objective of this paper is to discover how design of experiments can be used to scrutinize press quenching of bevel gears. The first part of this investigation shows how different process parameter settings influence geometry of the bevel gear. Based on the results of the experiments, predictions and statistical simulations, the outcome of the press quenching process can be estimated. Estimations for the number of defect parts then form the basis for evaluating whether the proposed tolerances meet the quality requirements. The work is based on an industrial case where 55 bevel gear crown wheels for heavy trucks are carburized and then case hardened in a Gleason press quenching machine.

Place, publisher, year, edition, pages
2012. 251-259 p.
Keyword [en]
Press quenching, Bevel gears, Design of experiments, Tolerance analysis, Process planning
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production
Identifiers
URN: urn:nbn:se:kth:diva-116504OAI: oai:DiVA.org:kth-116504DiVA: diva2:589965
Conference
Swedish Production Symposium SPS12; Linköpings University 6-8 november 2012
Funder
XPRES - Initiative for excellence in production research
Note

QC 20130909

Available from: 2013-01-21 Created: 2013-01-21 Last updated: 2014-05-22Bibliographically approved
In thesis
1. Process planning for precision manufacturing: An approach based on methodological studies
Open this publication in new window or tab >>Process planning for precision manufacturing: An approach based on methodological studies
2014 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Process planning is a task comprising a broad range of activities to design and develop an appropriate manufacturing process for producing a part. Interpretation of the part design, selection of manufacturing processes, definition of operations, operation sequences, machining datums, geometrical dimensions and tolerances are some common activities associated with the task. Process planning is also “the link between product design and manufacturing” with the supplementary commission to support design of competitive products.

Process planning is of a complex and dynamic nature, often managed by a skilled person with few, or no, explicit methods to solve the task. The work is heuristic and the result is depending on personal experiences and decisions. Since decades, there have been plenty of attempts to develop systems for computer-aided process planning (CAPP). CAPP is still awaiting its breakthrough and one reason is the gap between the functionality of the CAPP systems and the industrial process planning practice.

This thesis has an all-embracing aim of finding methods that cover essential activities for process planning, including abilities to predict the outcome of a proposed manufacturing process. This is realised by gathering supporting methods suitable to manage both qualitative and quantitative characterisation and analyses of a manufacturing process.

The production research community has requested systematisation and deeper understanding of industrial process planning. This thesis contributes with a flow chart describing the process planning process (PPP), in consequence of the methodological studies. The flow chart includes process planning activities and information flows between these activities.

The research has been performed in an industrial environment for high volume manufacturing of gear parts. Though gear manufacturing has many distinctive features, the methods and results presented in this thesis are generally applicable to precision manufacturing of many kinds of mechanical parts.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2014. xiii, 72 p.
Series
TRITA-IIP, ISSN 1650-1888 ; 14:04
Keyword
Process planning, precision manufacturing, machining, tolerance chain analysis, process behaviour, process performance, process capability, in-process workpiece.
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-145433 (URN)978-91-7595-172-0 (ISBN)
Public defence
2014-06-10, Sal M311, Brinellvägen 68, KTH, Stockholm, 13:00 (Swedish)
Opponent
Supervisors
Funder
XPRES - Initiative for excellence in production research
Note

QC 20140522

Available from: 2014-05-22 Created: 2014-05-20 Last updated: 2015-10-16Bibliographically approved

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