1、热处理工艺设计 有限元分析软件,Copyright DCT Inc. 2010,DANTE是以有限元为基础的热处理工艺模拟商业化软件. 可以精确模拟加热和冷却工艺中的传热过程. 经实验验证的力学模型、相变模型、渗碳模型和数据库. 可用于模拟液体浸入淬火、气淬淬火、快速淬火、模具淬火. 可用于模拟低温回火热处理工艺.,DANTE 热处理工艺分析软件,模拟分析结果 残余应力 碳分布 微观结构相分布 硬度分布 热处理变形预测,DANTE 功能介绍,残余应力,碳分布,怎样应用DANTE节约制造成本、提高设计质量？,通过软件来“模拟实验” 了解热处理工艺参数对变形，残余应力，微观组织和硬度的影响 确定造
2、成热处理变形、缺陷等问题的原因 排除热处理工艺问题、改进和优化热处理工艺 优点 在保证热处理质量的前提下降低热处理成本，比如渗碳时间 节约热处理零件后加工成本 提高热处理零件质量 热处理零件设计 在零件初始设计阶段考虑热处理的影响 对改新设计的热处理过程预测 DANTE 是经实验验证热处理模拟软件,CAD & Model Building,DANTE 模拟分析方法,微观组织,变形,残余应力,DANTE 模拟的典型零件,DANTE 软件的结构,零件热处理模拟 分析例子和验证,AISI 5120 齿轮坯油淬火工艺模拟,油淬火的程序: 奥氏体化温度: 870 C 渗碳炉碳势: 0.85% 淬火油温度
3、 (5 min.) : 132 C 空冷至室温 齿轮坯的尺寸:ID = 35 mmOD = 57 mmHeight = 22 mm轴对称网格: 380 elements,2D, Axisymmetric Model,Ring with Center Hub,渗碳过程,Microprobe vs. Simulation,AISI 5120 齿轮坯渗碳和油淬火后 模拟预测的微观相分布 (trace across mid-height),AISI 5120 齿轮坯渗碳和油淬火后变形预测,Comparison of Predicted & Residual Stress Profiles Calcul
4、ated from X-RAY and Neutron Diffraction Tests for 5160 Quenched Steel Bars,Oil Quenched & Tempered,Intensively Quenched & Tempered,圆柱件淬火回火后残余应力,AISI 1045 Steel 带导向槽轴形件,模拟结果和实验数据比较 变形、硬度、和微观结构,曲轴件热处理模拟,During Cooling,曲轴热处理模拟: 温度,曲轴热处理模拟: 奥氏体,曲轴热处理模拟: 切开面奥氏体,曲轴热处理模拟: 变形预测,飞机起落架热处理变形模拟预测,飞机起落架高度大约3.5米
5、材料: 300M,飞机起落架淬火过程中的温度场,飞机起落架淬火后的预测变形,变速器输出轴热处理过程中的温度场,变速器输出轴热处理过程中的应力场,齿轮经不同淬火工艺后的残余应力,10:1 maximum to minimum load ratio Servohydraulic test machine at 40 cps Runout is defined as 107 cycles without failure,Schematic of Test Fixturing,单齿疲劳强度试验,单齿疲劳强度试验数据: Benefit of REM,IQ 800 MPa 120 ksi,OQ 1000
6、MPa 148 ksi,Stress Free 1600 MPa 232 ksi,Stress State in Test Gear at 1400 lbs. Bending Load,MPa,单齿疲劳载荷下齿轮应力分布,AISI 4150 Oil Quench,AISI 9310 Carburization+ Oil Quench,齿轮设计过程中考虑材料选取 和热处理工艺?,利用残余压应力提高齿轮寿命或降低齿轮重量,齿轮动态疲劳测试应力重新分布:原设计,齿轮动态疲劳测试应力重新分布:优化设计,斜锥齿轮淬火模拟:温度和奥氏体,斜锥齿轮淬火模拟:最大最小主应力,油孔周围的温度场分布不均匀,汽车曲
7、轴件感应淬火过程模拟: 感应加热3.0秒后的温度场,奥氏体层大概 2.5 mm,汽车曲轴件感应淬火过程模拟: 感应加热3秒后奥氏体分布,汽车曲轴件感应淬火过程模拟: 冷却过程中两个关键位置的内应力变化,脱碳后的碳分布 脱碳层大约 0.1 mm.,齿轮热处理过程中表面脱碳模拟,表面脱碳对残余应力及淬火裂纹的影响,预测的表面拉应力很浅. 脱碳层的深度决定表面拉应力层的深度. 表面层的拉应力可能会造成淬火过程中或后加工中表面开裂. 表面拉应力层的深度大约是0.3 mm.,3D 单齿模型,端面齿轮模压淬火过程模拟,Axial Displacement After Press Quench with L
8、oad Still Appliedcontour plot shows the web bowing downward (red is positive in the downward direction)the top tooth has expanded upward by 0.24 mm (0.009”) and the bottom tooth has expanded downward by 0.02 mm (0.001”),Springback as Die Load is Removedtooth section lifts approximately 2.3 mm (0.090
9、”) after removing the press load and final cooling from the oil temperature of 140F to room temperature.,3D 单齿模型,端面齿轮模压淬火过程模拟 (cont.),Without Shimming,With Shimming,端面齿轮模压淬火过程模拟 (cont.),端面齿轮模压淬火后预测的残余应力,环形齿轮模压淬火过程模拟,3D 单齿模型,环形齿轮模压淬火后的变形,Scenario 4 45 seconds air transfer 100 seconds dwell,Scenario 6
10、 120 seconds air transfer 20 seconds dwell,Scenario 5 45 seconds air transfer 20 seconds dwell,加载前下模对齿轮冷却的影响,热处理后残余应力预测,Unit: MPa,Press Quench Scenario 4,热处理后齿轮加工过程中的变形,DANTE 模型和数据库 传热模型: 加热和冷却热边界 碳扩散模型 相变模型 力学模型,利用热电偶数据反求热边界条件,Data Acquisition Time - temperature data from thermocouples Data Analysi
11、s Using optimization or reverse calculation to determine heat transfer coefficients,利用热电偶数据反求热边界条件 (Cont.),碳扩散模型,Establishes carbon profile within the component during carburization Mass diffusion model is applied Modeling furnace gas carburizing processes Surface carbon potential following time dep
12、endent curve based on a rise to equilibrium carbon level Modeling vacuum carburizing processes Surface carbon flux in terms of the carburizing schedule,Custom kinetics model: Kinetics based on dilatometry data Kinetics based on TTT curves Kinetics based on CCT curves Kinetics based on Jominy data Gl
13、obal kinetics model: The user inputs the chemistry to calculate phase volumes based on cooling path, or to calculate Jominy hardness DANTE kinetics predict: Volume fractions of ferrite, pearlite, bainite, and martensite throughout an arbitrary cooling path Kinetics verification: Run DANTE dilatometr
14、y model, and compare with the experiments Run DANTE utilities to obtain TTT (CCT) curves, and compare with references Run DANTE Jominy end-quench model, and compare with experiments,相变模型及参数确定,典型热及相变膨胀试验,利用热及相变膨胀来测量确定相变模型参数,Jominy Checking,Fitting Tolerance,Dilatometry Fitting,TTT Fitting,相变模型参数的拟合方法
15、,DANTE 力学模型,Defines mechanical properties for each phase as a function of %C, T, , Embedded mixture model calculates the mechanical behavior of composite from mechanical behavior of individual phases Accounts for transformation induced plasticity Effectively calculates the material response during l
16、oading, unloading, and reverse loading,* DANTE uses the IR100 Award winning BCJ Material Model developed at Sandia National Laboratory,利用传统应力-应变数据拟合 力学模型参数,Phase Transformation Kinetics Fitting for Heating & Cooling Uses dilatometry data Uses TTT & CCT or CHT data Uses Jominy data (cooling) TTT, CCT
17、, and Jominy Diagram Generator Mechanical Parameters Fitting Uses temperature dependent compression and tension test data Heat Transfer Coefficient Determination Uses thermocouple data DANTE/GCARB for Gas Carburization Process Design (Time, Temperature, and Carbon Potential) DANTE/VCARB for Vacuum C
18、arburization Boost/Diffuse Schedule Design.,DANTE 附属工具,DANTE 软件购买选择 - Annual Licensing (Seat) - Perpetual Software Licensing with Maintenance Agreement - Training & Trial License- Tools & Utilities Mechanical Data Fitting Kinetics Fitting Jominy Hardness Predictor,Deformation Control Technology, Inc
19、. provides consulting services on both heat treatment modeling and metallurgical works.Deformation Control Technology, Inc. also provides DANTE licenses. Annual Licensing (Seat). Perpetual Software Licensing with Maintenance Agreement Training & Trial License. Utilities to support the DANTE software, including both mechanical and phase transformation kinetics fitting.,DCT 热处理模拟和咨询服务,联系方式: Deformation Control Technology, Inc. 7263 Engle Road, Suite 105, Cleveland, Ohio, USA Phone: (440) 234-8477 Fax: (440) 234-9140 E-mail: supportDeformationC Website: www.DeformationC,
