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Alternative Methods for Heat Stress Relief

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Alternative Methods for Heat Stress Relief 2007:277 CIV MASTER’S THESIS Alternative Methods for Heat Stress Relief Stefan Lindqvist Jonas Holmgren MASTER OF SCIENCE PROGRAMME Mechanical Engineering Luleå University of Technology Department of Applied Physics and Mechanical Engineering Division of Manufacturing Systems Engineering 2007:277 CIV • ISSN: 1402 - 1617 • ISRN: LTU - EX - - 07/277 - - SE Universitetstryckeriet, Luleå Alternative methods for heat stress relief Preface As a final element in the Masters of Science degree at Luleå University of Technology a master thesis is conducted by the student. This is usually carried out in cooperation with the responsible tutor and a company with a connection to the student’s direction of interest. The master thesis lasts one term and can be performed at the University or on site at the company. The student attains a degree in chosen direction of interests after passed verbal presentation and written report both at the company and at the University. We have chosen to perform our master thesis at Ferruform AB in Luleå at the department for axle production. The thesis work has been carried out during June to December 2007 and involved investigations of alternative methods for heat stress relief. The work has been instructive and interesting and a good basis for future work within the manufacturing industry has been attained. We would like to thank all involved personnel that have been helpful during our work. Great thanks go to our supervisor at Ferruform, Peter Lundkvist, for guidance and advice to our thoughts during the work period. We also say thanks to our tutor and examiner at Luleå University of Technology, Hans Engström. Luleå 14th of December 2007 ______________________________ Jonas Holmgren ______________________________ Stefan Lindqvist Alternative methods for heat stress relief Abstract Ferruform AB in Luleå is a manufacturer of chassi components for Scania’s truck production. At the department for Axle production sheet metal is processed to produce rear axle housings. The main processes include shearing, forming, welding and machining. High amount of residual stresses are built up in the material because of the extensive weld operations. Residual stresses are reduced with a very time and energy consuming heat treatment method called heat stress relief. The purpose with this thesis was to investigate alternative methods for heat stress relief and then suggest the best solution for Ferruform. Our main tasks in this thesis has been literature studies, investigation of prior work, market analysis, contact and visits from suppliers, production tests and weekly meetings with our supervisor. Finally we have presented the thesis verbally at the company and at Luleå University of Technology. A written report has also been made. Two alternative methods for heat stress relief has been found and further investigated. Tests have been made regarding these two methods for stress relief. One test with a method called vibratory stress relief and one test with a simulated bend-straightening operation. Layouts have been created to easier visualize the space required for the different methods. Seen from the layouts is that both methods requires less space than the heat stress relief oven. Single piece flow is achieved with bend-straightening and batched flow is achieved with vibratory stress relief. Bend-straightening provides single batch flow, low cycle times and is utilized by a competitor, therefore it is recommended as a primary option to heat stress relief at Ferruform. However, verification tests have to be made in order to evaluate the effects of the two different alternative methods. We have suggested that a fatigue test with spectrum loads should be carried out in order to get a reliable result. Also a third method is taken into account in this thesis, hot formed banjo halves. This is not an option for Ferruform but may be an alternative to Scania Sao Paolo in Brazil. Alternative methods for heat stress relief Sammanfattning Ferruform AB i Luleå tillverkar chassikomponenter till Scanias lastbilsproduktion. Vid avdelningen för Axelproduktion utförs förädling av plåt till färdig bakaxelbrygga. De processer som utförs är huvudsakligen klippning, formning, svetsning, bearbetning. På grund av omfattande svetsoperationer byggs svetsegenspänningar in i materialet som kan orsaka geometriavvikelser och minskad livslängd. I nuläget utlöses dessa svetsegenspänningar med en mycket tids och energikrävande metod kallad avspänningsglödgning Syftet med examensarbetet var att undersöka vilka alternativa metoder till Avspänningsglödgning som finns idag samt rekommendera den bästa lösningen utifrån Ferruform’s perspektiv. Våra huvudsakliga arbetsuppgifter har inneburit en rad olika moment som innefattat litteraturstudier, undersökning av tidigare arbeten, marknadsundersökningar, kontakt och besök av leverantörer, tester i produktion samt återkommande veckomöten med handledare. Slutligen har vi redovisat muntligt på företaget och vid Luleå tekniska universitet samt skrivit en rapport. Två potentiella alternativa metoder för avspänningsglödgning har undersökts närmare. Tester har utförts med dessa två alternativa metoder till avspänningsglödgning. Ett test utfördes med en metod kallad vibrationsavspänning och ett test med en simulerad riktningsoperation. Layouter har tagits fram för att lättare kunna visualisera det utrymme metoderna upptar. Man kan se från layouterna att båda metoderna upptar mindre utrymme än den nuvarande avspänningsglödgningen. Enstycksflöde fås med riktningsmetoden medan ett batchflöde fås med vibrationsavspänning. På grund av att riktningsmetoden ger enstycksflöde, låg cykeltid samt används av konkurrent gör det den till den metod som rekommenderas i första hand på Ferruform. Dock måste ett verifikationstest göras för att kunna utvärdera effekterna av de två alternativa metoderna. Vi har föreslagit att ett utmattningstest med varierande lastpåkänning bör utföras för att kunna erhålla ett så tillförlitligt resultat som möjligt. Även en tredje alternativ metod har undersökts i detta arbete, varmformade banjohalvor. Detta är inte en metod som lämpar sig för Ferruform men kan vara ett alternativ för Scania Sao Paolo i Brasilien. Alternative methods for heat stress relief Nomenclature Relaxation Reduction of residual stresses Jolting Forging operation Dislocation A linear crystalline defect around which there is atomic misalignment Banjo Part of rear axle housing Wedge Reinforcement part in rear axle housing RT Room temperature Alternative methods for heat stress relief Table of Contents 1 INTRODUCTION ................................................................................................................................. 1 1.1 COMPANY BACKGROUND................................................................................................................. 1 1.2 CURRENT SITUATION ....................................................................................................................... 2 1.3 PROJECT DESCRIPTION..................................................................................................................... 2 1.4 GOAL ............................................................................................................................................ 3 1.5 LIMITATIONS................................................................................................................................... 3 2 PLANNING ........................................................................................................................................... 4 3 THEORY ............................................................................................................................................... 5 3.1 WELDING........................................................................................................................................ 5 3.1.1 MIG/MAG- welding, Gas metal arc welding............................................................................... 5 3.1.2 Resistance welding..................................................................................................................... 6 3.1.3 Weld zones................................................................................................................................. 7 3.2 RESIDUAL STRESSES CAUSED BY WELDING ....................................................................................... 8 3.3 FATIGUE ......................................................................................................................................... 9 3.3.1 Causes..................................................................................................................................... 10 3.4 FATIGUE STRENGTH....................................................................................................................... 10 3.5 FACTORS AFFECTING FATIGUE ....................................................................................................... 11 3.5.1 Type of load............................................................................................................................. 11 3.5.2 Range of stress......................................................................................................................... 11 3.5.3 Mean stress.............................................................................................................................. 11 3.5.4 Construction design ................................................................................................................
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