Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling

The service life of rolling contacts is dependent on many factors. The choice of materials in particular has a major influence on when, for example, a ball bearing may fail. Within an exemplary process chain for the production of hybrid high-performance components through tailored forming, hybrid so...

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Bibliographic Details
Published in:Metals (Basel ) 2020-10, Vol.10 (10), p.1336
Main Authors: Kruse, Jens, Mildebrath, Maximilian, Budde, Laura, Coors, Timm, Faqiri, Mohamad Yusuf, Barroi, Alexander, Stonis, Malte, Hassel, Thomas, Pape, Florian, Lammers, Marius, Hermsdorf, Jörg, Kaierle, Stefan, Overmeyer, Ludger, Poll, Gerhard
Format: Article
Language:English
Subjects:
Alloy steels
Ball bearings
Bearings
Cladding
Computer simulation
cross-wedge rolling
Finite element method
forming
Laser beam welding
Laser deposition
Lasers
LMD-W
Materials selection
Mathematical analysis
Metal fatigue
Metal forming
PTA
Residual stress
Service life
Shear stress
Simulation
tailored forming
Thickness
welding
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Summary:The service life of rolling contacts is dependent on many factors. The choice of materials in particular has a major influence on when, for example, a ball bearing may fail. Within an exemplary process chain for the production of hybrid high-performance components through tailored forming, hybrid solid components made of at least two different steel alloys are investigated. The aim is to create parts that have improved properties compared to monolithic parts of the same geometry. In order to achieve this, several materials are joined prior to a forming operation. In this work, hybrid shafts created by either plasma (PTA) or laser metal deposition (LMD-W) welding are formed via cross-wedge rolling (CWR) to investigate the resulting thickness of the material deposited in the area of the bearing seat. Additionally, finite element analysis (FEA) simulations of the CWR process are compared with experimental CWR results to validate the coating thickness estimation done via simulation. This allows for more accurate predictions of the cladding material geometry after CWR, and the desired welding seam geometry can be selected by calculating the cladding thickness via CWR simulation.
ISSN:2075-4701
2075-4701
DOI:10.3390/met10101336