Computer modeling and validations of steel gear heat treatment processes using commercial software DANTE

The heat treatment process of a gear made of AISI 9310 carburized steel is modeled using the commercial heat treatment simulation software DANTE. Both carburization and quenching processes affect the residual stress distribution and distortion of heat-treated parts, which are important to service quality and fatigue life. DANTE/VCARB is used to design the boost/diffuse schedule of a vacuum carburization process. Oil quenching is modeled following the vacuum carburization process. Thermal gradient and phase transformation are two main sources of distortion and residual stresses in quenched parts. The relation of the carbon distribution, thermal gradient, and phase transformations during quenching is studied through the gear modeling example. Because of geometry, the residual stress distribution after quenching is non-uniform along the gear surface. In general, the root fillet has higher residual compression than either the root or tooth face locations after traditional oil quenching of carburized gears. The predicted residual stresses from the oil quenching model are imported into a single tooth fatigue bending model. The gear stresses under bending load indicate the possible cracking locations during the bending fatigue test. The importance of heat treatment residual stresses during gear design is pointed out, and it is commonly ignored in the gear design and manufacturing industry.     

Finite Element Simulation of Processes Involving Moving Heat Sources. Application to Welding and Surface Treatment

IntroductionAwiderangeofweldingorsurfacetreatmentprocessesinvolvetheuseofaheatsourcemovingataconstantspeedoverthesurfaceofthecomPonent.ThreedimensionalcomPutationofresidualstressesanddistortionsinducedbythiskindofprocesses,usingtheusualfiniteelementmethod,needsveryrefinedmeshesinordertocorrectlydescribethepropertiesandstressgradientsintheheataffCctCdzonealongthepathoftheheatsource.Inthispaper,wediscussthedifferentnumericalaPproaches,imPlementedinSYSWELD@software,whichcanbeusedtodorealisti…     

Prediction of Welding Residual Stress in 2. 25Cr-1Mo Steel Pipe

Introduction2.25Cr-1Mo-steel is widely used in thepetroleum industry and in steam power generatingof both nuclear and conventional power plants be-cause of its excellent high-temperature strength,corrosion resistibility,and resistance to high-tem-perature hydrogen attack.Because several alloy el-ements are added into2.25Cr-1Mo-steel,marten-site is prone to form after welding.It has been rec-ognized that phase transformation can radically af-fect the development of residual stresses[1-2].Inor…     

磨削淬火技术的温度场仿真研究

目前对磨削淬火的研究,多采用实验的方法,通过大量的实验来制定合适的工艺参数,但由于磨削加工的复杂性,常使得实验研究带有一定的偶然性和盲目性.文中对影响磨削淬火工艺的关键因素——温度场,利用有限元方法进行了仿真研究,得到了磨削温度场的等温线图和工件各处的温度变化历程,预测了工件表层是否发生马氏体相变及相变层厚度,并进行了实验验证.研究表明,磨削淬火技术可以替代常规表面淬火工艺,利用磨削温度场仿真技术可以减少实验量、节省实验费用.     

RECENT DEVELOPMENT OF PROCESS SIMULATION AND ITS APPLICATIONS TO MANUFACTURING PROCESSES

l.IntroductionThemostboortantdrivingforceinmanufacturillistoPrOduCeabetterPrOductatalowercost.GenerallyeffecthemethodsinchideshOrtenintheleadtiminthedesigncyCle,andredUcinthetoolingcostandmaChinedOWnmeatProductionst4e.AllOfthemrewtabettertmderstandingofhO…     

线接触零件磨损过程的数值仿真及试验研究

磨损寿命预测，磨损状态监测及摩擦副参数优化是摩擦副系统的磨损过程中的三大难点。本基于离散数学理论和计算机技术提出一种数值仿真模型，可用于解决复杂动态非线性系统的磨损问题。     

舰船发动机排气管内顺流喷雾降温的CFD分析

发动机排气管废气出口温度过高是影响舰船红外隐身性能的重要因素之一.在排气管内喷雾能有效降低废气出口温度.针对排气管内顺流喷雾时的气液两相湍流流动与热质传递,用Euler-Lagrange方法建立了数理计算模型,用CFD计算软件进行了数值模拟.考察了水雾出口温度、水流量、水雾喷射夹角及雾滴初始粒径对喷雾降温效果的影响.结果表明:排气管内顺流喷雾时,废气出口温度大幅降低,呈倒钟形分布;废气出口温度的大小和分布与水流量、水雾喷射夹角及雾滴初始粒径息息相关;水流量越大、雾滴初始粒径越小,则废气出口温度越低,废气出口温度与水流量的大小基本呈线性关系;雾滴初始粒径越小、水雾喷射夹角越大,则废气出口温度分布越均匀;而废气出口温度的大小与分布对水雾出口温度的变化并不敏感.     

Calculation of Temperature Field During Laser Transformation Hardening of Cylindrical Bodies

IntroductionLaserTransformationhardeningtechniquehasbeensuccessfullyusedinindustryformanyyears.AlotsoftheoreticalworkshasbeendoneforheatflowduringthelasertfansformationhardeningofflatworkPieces["].Cyindricalbodiesarewidelyusedinindustrysuchaslocomotivecrankshaft,steelrollervalyeseat,enginecyinder.IftheschcesoftheseworkPiecesaretreatedbylasertheirwearresistancewiIIimProvealot.UptillnowmanyexPerimentalworkshasbeendoneforlasertransformationhardeningofcyindricalbodies,butfewtheoreticalworkshav…     

纯六方相钛酸锌粉体制备和表征

采用溶胶-凝胶法,用Ti（OC4H9）4、Zn（NO3）2.6H2O、无水乙醇、冰醋酸等原料,利用直接升温和保温-升温两种方法合成超细的六方相ZnTiO3粉体.利用TG-DSC、XRD、SEM等测试分析手段对凝胶的热分解、相转变以及粉体结构形貌进行了表征.实验结果表明：ZnTiO3凝胶的热分析中,前躯体的热重变化主要分为三个阶段,其中DSC曲线在770820℃和850930℃间有多个小的吸热放热峰出现,对应于复杂的相变.在粉体制备过程中,先于700℃保温3 h再850℃加热5 h的处理,可以获得单一的六方相Zn-TiO3粉体.     

Finite Element Method Analysis of Stress Field Considering Thermal Coupled Force During Laser Process

IntroductionLaserphasetransformationhardeningisanewtechnologyduringwhichlaserheatresourceactsdirectlyonsurfaceofmaterialandcompositionscharacteristicofmaterialischanged.Thetechnologyproce8sesacharacterofrapidheatvelocity,highheattempelatureandquickcoolingspeed(l0'col0'aC/s).Thecompositionandcharacteristicofmaterialvariedwithvariousinnertemperaturewillleadtothermalresidualstress.Itiswellknownthattheresidualstressaffectssignificantlyoncharacteristicofmaterial,suchasimProvingstrengthoffatigUere…     

Formation of nanometer coherent structures during spinodal decomposition and ordering coexistence phase transformation in Fe-24Al alloys

The nanometer coherent structure evolution of spinodal decomposition and ordering coexistence phase transformation in Fe-24Al alloys is investigated by the microscopic phase field kinetic model. The results show that the concentration and long-range order parameters all continuously change towards to their equilibrium values during phase transformation. With the increase of elastic interaction energy, the anisotropy along [01] or [10] elastic soft direction is more obvious and the time reaching equilibrium state is also shortened. According to the results, the formation of nanometer coherent structures during phase transformation is composed of the initial decreasing stage of order degree stage, the incubation stage, the continuous increasing stage of concentration order parameter and long-range order parameter, and the later stable stage. The spinodal decomposition and ordering is interaction; the initial ordering stage is a necessary condition of the coexistence phase transformation. The nanometer coherent structures are not found to grow during the whole phase transformation. The simulation results are in accordance with the results in experiment obtained by the aging treatment in Fe-24Al alloys.     

Transformation Plasticity─The Effect on Metallo-Thermo-Mechanical Simulation of Carburized Quenching Process

IntroductionInelashcorhaersiblestrainaccompaniedbyslidingofcrystalsduetothermalandphasetransformationdilatationiswellknowntointensivelythethedistonionofworkpieceunderqUopching,andsomanynumericalsimulatonsll-7]havebeencAnedoutintheframeworkofmotallochermo-mechwhcsl1].Transformationplasticity(TP),anothekindofbeversiblestrain,isalsorecognizedasoneofdominantparwtersthechngthestr6ssanddistorton,andsomenumcricalcalculationaremadebytakingtheeffectintoconsideration.Figurelschematicallyillustraresthe…     

按非平稳随机过程模拟自然风速的一种数值方法

基于数据的第二种非平稳随机过程数学模型是第一种非平稳随机过程数学模型的继续。该方法根据有限的原始风速记录 ,通过快速富氏变换和希尔伯特变换 ,建立了非平稳随机过程数学模型 ,然后以数字模拟的方法产生所需的随机样本。根据第二种非平稳随机过程数学模型和观测的风速记录 ,进行了风速样本模拟     

Numerical Study of the Plastic Behaviour of a Low Alloy Steel during Phase Transformation

IntroductionItiswellknownthaphasetrapsformationsplayanimPortantroleontheresidualstressesandstrainsinducedbythermalprocessessuchasweldingandquenching.lnthispaPer,wefocusourattentiononthebehaviourofsteelsduringphasetransformations.AtheoreticalaPproachhasbeenachievedbyLeblondetal[1]andhasledtOamacroscopicmodelinthecaseofideal-plasticphases[2][3].Thenthemodelhasbeengeneralizedtotakestrainhardeningphenomenaintoaccount[4].ThetheoreticalaPproachhasbeenassessedandcompletedusingflniteelementsimulati…     

金属再结晶组织模拟及实验对比研究

金属再结晶过程计算机组织模拟,可以仿真实验中观测不到的组织演变细节,得到定量的特征参数,预报退火后的材料性能,指导热处理工艺设计。构建一个新的静态再结晶MC Potts模拟模型,并以1060铝合金为研究对象,进行再结晶模拟与实验对比研究。结果表明,1060铝合金表现出明显的再结晶特征,得到了近似等轴晶组织;新模型模拟的再结晶形核位置、组织形貌与实验结果一致,组织演变过程也与实验结果基本一致,但模拟的再结晶等轴晶与实验近似等轴晶不完全一致,模拟的再结晶速度也低于实验结果。     

Generalization of Results of Computations and Natural Experiments at Steel Parts Quenching

IntroductionThepaPerpresentsthegenera1izationofresultsofnumericalcomputationsandnaturalexperimentsbasedonthesimilaritytheoryandtheoryofregularthermalconditions.Thenumericalcomputationshasbeenmadeonthebasisofsolvingequationsofnon-stationarythermalconductivityandthermoplaSticity.Thegeneralizationofresultsliesinthefactthatwefoundadimensionlessformulaforthedeterminationofthetimeofreachingthemaximumcompressionstressesonthesurfaceofp8rtstobequenched.ThepatstobequenchedaredividedintothreegrouPs:pla…     

GPS坐标向北京54坐标转换的方法

GPS测量得到的是WGS-84的地心空间直角坐标,而工程中通常使用地方独立坐标系。两者的转换方法一般分为平面转换模型和空间转换模型。平面转换模型原理简单,数值稳定可靠,但只适用于小范围的CPS测量;空间转换模型可用于大范围的CPS测量,按实际情况又分为七参数转换和三参数转换两种。对这两种转换模型进行介绍。     

Research and Application Prospect of Computer Simulation on Heat Treatment Process

AseriesofgreatProgresseshavebeenachievedintheresearchofheattrCtoelltmathematicalmodelandcomPotersimulationduringrecellttenyears.ThecouPlingbforeentemPerthee-phasetransformation-stressl'-'],threedimensionalnon-linearFEManalysis[#-'],thecalculationofphasetransformationkinetics['-'],theeffectofstressonphasetransformationkineticsl,'-,,],thedealingwithabruPchangedboundnyconditionsl"#],thesimulationonfludfield["l,andotherinveshgationshavecarredout,andtheirachievementshaveProvidedasoundbasisfo…     

基于状态参量的饱和砂土剪胀性本构模型

现有的边界面模型多用临界状态区分松砂、密砂,但试验中,很难确定密砂的临界状态.本文以相变线（PTL）为参考线,引入以相变状态为基础的状态参量,将已有的边界面模型加以改进利j用状态参量的概念,可以准确判断砂土在初始时刻和任意时刻的变形趋势,而基于状态参量的剪胀比在相变点处仍等于零.无论是松砂还是密砂,或砂土从一种状态到另一种状态,基于状态参量的剪胀都能真实的模拟砂土的反应.研究结果表明,利用本文的模型参量得到的密砂三轴排水试验,模拟结果与试验结果相吻合,较好地反映了砂土的力学特征.     

Integrated fluid-thermal-structural numerical analysis for the quenching of metallic components

The quenching of a metal component with a channel section in a water tank is numerically simulated. Computational fluid dynamics (CFD) is used to model the multiphase flow and the heat transfer in film boiling, nucleate boiling and convective cooling processes to calculate the difference in heat transfer rate around the component and then combining with the thermal simulation and structure analysis of the component to study the effect of heat transfer rate on the distortion of the U-channel component. A model is also established to calculate the residual stress produced by quenching. The coupling fluid-thermal-structural simulation provides an insight into the deformation of the component and can be used to perform parameter analysis to reduce the distortion of the component.