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Straightening of distorted components  after heat treatment is often a necessary operation. The straightening operation leads to local plastic deformation, which is affecting the residual stress state, the hardness, and ultimately the fatigue strength of the component. The present study evaluates the influence of a straightening operation on fatigue strength and on the residual stress state of induction hardened shafts of steel EN 42CrMo4. A simplified FEM model was formulated. The model showed that the residual stress state was asymmetric along the circumference of a straightened shaft. Fatigue testing was performed in a three point bending and showed that the fatigue strength was reduced by up to some 20 % by heavy straightening. A fracture mechanics model for fatigue crack growth and arrest was developed. The model could be used to predict the fatigue strength of a straightened shaft provided that the residual stress state was known.

Straightening of induction hardened shafts – influence on fatigue strength and residual stress