A change in component design could help achieve objectives in lightweight construction. However, lightweight component design can incur serious distortion problems after the final heat treatment due to reduced stiffness or asymmetries in the mass distribution. The analysis of design modification through geometrical variations and their consequences on the distortion behavior through experiments can be costly and time consuming. In this paper, using 3D simulation models, different modified lightweight geometries are simulated. Using these simulation results, the authors try to understand the complex distortion behavior and correlate it with the effects of design modification.
Keywords: SAE 5120 (20MnCr5); case hardening; counter gear; distortion; lightweight construction; numerical simulation.