Improving Control Of A Quenching Process By Coupling Analysis Methods
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Improving Control of a Quenching Process by Coupling Analysis Methods
Intensive quenching is a fast transient thermal process where an austenitized part is cooled rapidly by contact with a stream of high velocity water. As in all quenching processes, the quenchant flow condition has a primary effect on material response, including the final microstructural phase distribution, hardness, residual stress, and distortion. Therefore, characterization of the quenchant flow is important for understanding the quenching process and the relationships between quenchant flow rate, part cooling rate, material phase transformations, and residual stress. With the development of high-speed computer and computational fluid dynamics (CFD) technologies, the quenchant flow pattern around a complex part during quenching can be calculated. This allows the local heat transfer between the quench media and the part to be calculated. The transient heat transfer coefficients predicted from such a CFD model can then be used in a finite element based thermal-stress calculation to predict the final residual stress state of the part, as well as the microstructural phase distribution, hardness distribution, and dimensional change due to quenching. In this paper, transient CFD analyses using FLUENT are applied to characterize the water flow and thermal boundary conditions around a spur gear made of carburized Pyrowear 53 during intensive quenching. The calculated heat transfer coefficients are imported to DANTE heat treatment models, and the gear's response to intensive quenching is predicted. The results include hardness, phase transformation, stress, and distortion. The relationships between temperature field, phase transformation, residual stress, and distortion during quenching are explained using the modeling histories. The combination of FLUENT and DANTE models provides efficient and effective solutions to the quenching fixture and water flow designs. The predicted gear distortion and residual stresses are validated using experiments.
Comprehensive Materials Processing
Comprehensive Materials Processing, Thirteen Volume Set provides students and professionals with a one-stop resource consolidating and enhancing the literature of the materials processing and manufacturing universe. It provides authoritative analysis of all processes, technologies, and techniques for converting industrial materials from a raw state into finished parts or products. Assisting scientists and engineers in the selection, design, and use of materials, whether in the lab or in industry, it matches the adaptive complexity of emergent materials and processing technologies. Extensive traditional article-level academic discussion of core theories and applications is supplemented by applied case studies and advanced multimedia features. Coverage encompasses the general categories of solidification, powder, deposition, and deformation processing, and includes discussion on plant and tool design, analysis and characterization of processing techniques, high-temperatures studies, and the influence of process scale on component characteristics and behavior. Authored and reviewed by world-class academic and industrial specialists in each subject field Practical tools such as integrated case studies, user-defined process schemata, and multimedia modeling and functionality Maximizes research efficiency by collating the most important and established information in one place with integrated applets linking to relevant outside sources
Quenching and the Control of Distortion
The November 1996 conference focused the same objectives as the first: obtain a global assessment of quenching technology and provide an integrated view of quenching, distortion and residual stress using an interdisciplinary approach. Nine papers presented at the Professor Imao Tamura Symposium show