++机车车轮有限元2008-3D FEM simulation of steel quenching and investigation of the effect o

j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 7 ( 2 0 0 8 ) 211–221
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Received 17 July 2007 Received in revised form 8 December 2007 Accepted 19 December 2007
Keywords: Steel Quenching Simulation Residual stress Phase transformation Finite element method
Quench hardening is a common process to produce steel components with reliable service properties such as high strength, hardness and wear resistance. Although it is a vital part of production based on steel, it is also one of the major causes of rejected components, production losses and the components that need to be reworked. Distortion, cracking, achievement of desired distribution of microstructure and residual stresses are considered to be the most important problems during quenching of steels, which render the prediction and control of the as-quenched state of the component into a vital process in order to achieve production goals. A number of studies have been conducted to simulate quenching. For the sake of brevity, only the studies that have
been directly used in the development of the current model have been cited in this paper. The reader is referred to Mackerle’s bibliographic work for an extensive literature review on the subject (Mackerle, 2003). Yu et al. (1978a,b) have made an extensive study on the generation of thermal stresses during quenching of steel cylinders of various diameters. Ericsson et al. (1982) predicted residual stresses caused by quenching of carburized steels. Fernandes et al. (1985) proposed a mathematical model for coupling of phase transformations with temperature field during quenching process by addition of an internal heat source term in the Fourier’s heat conduction equation. Denis et al. (1985) reviewed stress-phase transformation interactions and proposed some basic principles in calculation of internal stresses. Leblond, 1989; Leblond et al., 1989 reviewed mechano-metallurgical coupling by investigat-
Corresponding author. Tel.: +90 312 2105832; fax: +90 312 2102518. E-mail address: e106117@.tr (C. S ¸ ims ¸ ir). 0924-0136/$ – see front matter © 2008 Elsevier B.V. All rights reserved. doi:10.1016/j.jmatprotec.2007.12.074
Department of Metallurgical and Materials Engineering, Middle East Technical University, Balgat, 06531, Ankara, Turkey
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Article history:
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3D FEM simulation of steel quenching and investigation of the effect of asymmetric geometry on residual stress distribution
¨ Caner S ¸ ims ¸ ir ∗ , C. Hakan Gur
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j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 7 ( 2 0 0 8 ) 211–221
ing the transformation plasticity and the main effects of stress on phase transformation behavior. Inoue and Arimoto (1997) simulated various heat treatment and manufacturing processes based on the metallo-thermo-mechanical theory. Gur and Tekkaya (1996, 2001) developed a finite element model for predicting the temperature and stress/strain field during quenching of axisymmetric steel components. Later, Gur (2002) also carried out an experimental study on the effect of specimen geometry on the distribution of residual stresses and microstructure for quenched and tempered plain carbon and low alloy steels. Finally, Simsir and Gur (2005) investigated the effect of specimen geometry on residual stress distribution and distortion during the quenching of eccentrically drilled cylinders without phase transformations. Current study is an extension of this study and the reader is referred to previous paper for results without phase transformation effects. Although there are many publications on simulation of quenching, most of the research on this field is focused on components having planar, axisymmetric or cyclic symmetric geometries such as disks, cylinders, shafts, gears, etc. Factors affecting residual stress state and distortion have been long discussed and the basic knowledge on rough prediction of those parameters without performing FE simulations is currently available for such geometries (Todinov, 1998). However, real engineering problem arises during the prediction of distortion and residual stress state after quenching of asymmetric 3D components. In this study, an efficient 3D FEM based model capable of predicting distortion, microstructure and stress distribution during quenching was developed. Proposed model was integrated into commercial finite element software Msc.Marc® via user subroutines. Verification of the model was performed by X-ray diffraction (XRD) residual stress measurements. In the experimental part, hollow C60 steel cylinders having eccentrically drilled holes are quenched from 830 ◦ C into water at 20 ◦ C. After the quenching processes, tangen-