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7/25/2019 FORGE Simulation Surface Hardening Techniques
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FEM SIMULATION OF SURFACE HARDENING TECH
- APPLICATIONS TO GEAR COMPONENTS -R.DUCLOUX 1 , S. ANDRIETTI 1 , J. BARLIER 1
1 TRANSVALOR SA - FRANCE 5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
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INTRODUCTION
SURFACE HARDENING TECHNIQUES
CASE STUDY#1 : HEAT TREATMENT OF A BEVEL GEAR
CASE STUDY#2 : INDUCTION HARDENING OF A SPUR GEA
CONCLUSION & PERSPECTIVES
5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
OUTLINE
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INTRODUCTION
Standard goals of forming process simulations
- Understand material flow : underfilling, folds & laps
- Determine optimum forming sequence : reduce design cycle
- Predict material properties : grain flow, microstructure
- Extend die life : stress analysis, wear, load,
Productivity, Quality, Innovation & Savings
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INTRODUCTION
Recent challenges
- Predict the in -use properties of the forgings
- Simulate the entire manufacturing process including all pre & forming operations (from initial heating to final heat treatment)
Todays presentation- Illustrate a wide range of heat treatment simulations- Application to surface hardening on forged components
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INTRODUCTION
SURFACE HARDENING TECHNIQUES
CASE STUDY#1 : HEAT TREATMENT OF A BEVEL GEAR
CASE STUDY#2 : INDUCTION HARDENING OF A SPUR GEA
CONCLUSION & PERSPECTIVES
5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
OUTLINE
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5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
SURFACE HARDENING TECHNIQUES Goal of surface (or case) hardening
- Increase wear resistance and surface hardness- Keep inner metal softer- Applicable to low carbon & alloy steel- Followed by heat treatment to get desired hardness- Typical parts are : pinion, camshaft, gear,
Among the most common techniques- Carburizing- Nitriding, other diffusion processes- Induction hardening
- Shot peening
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5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
SURFACE HARDENING TECHNIQUES
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SURFACE HARDENING TECHNIQUES
Application of surface hardening on gear componentsVery located and non-constant contact areaNeed to increase hardness on the surfaceNeed to maintain ductility in the core of the component
Source : http://science.howstuffworks.com/transport/engines-equipment/gear4.htm
Source : http://www.yourdictionary.com/bevel-gear
Source : http://science.how
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INTRODUCTION
SURFACE HARDENING TECHNIQUES
CASE STUDY#1 : HEAT TREATMENT OF A BEVEL GEAR
CARBURIZING -> QUENCHING -> TEMPERING
CASE STUDY#2 : INDUCTION HARDENING OF A SPUR GEA
CONCLUSION & PERSPECTIVES
5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
OUTLINE
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CASE STUDY#1 : AUTOMOTIVE BEVEL GEAR
Complete forming sequence descriptionTwo warm forging stagesPiercing-Flash trimming, MachiningHeat treatment operations (carburizing-quenching-tempering)
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CASE STUDY#1 : PROCESS DATA Automotive bevel gear
Max outer diameter ~ 52 mm
Weight ~ 180 g Low carbon steel for carburizing (e.g. 20MnCr5)
Carburizing conditions Process : 2h40 at 850C Initial carbon rate in the part : 0.20% Atmosphere enriched in carbon : 0.8%
Quenching Oil bath : 20C during 2min HTC : 5500 W/C.m 2
Tempering To relieve internal stresses : 200C during 40min
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CASE STUDY#1 : CARBURIZING STAGE
Objectives of the carburizing stageIncrease of carbon concentration on surfaceIncrease quenchability for low carbon steel
0.20% carbon~
Lowquenchability
0.80% carbon~
Highquenchability
Isothermal diagram is shifted a
from 0.2
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CASE STUDY#1 : CARBURIZING RESULTS
Carbon concenafter carburizin
Carburizing
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CASE STUDY#1 : QUENCHING RESULTS
Phase distribution after oil quenching(martensite-bainite-pearlite-ferrite)
Residual stress d(1 st princip
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CASE STUDY#1 : PART DISTORTION
Distortion observed on the component after quenching due to plastic deformation(magnification x10)
Quenching
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CASE STUDY#1 : TEMPERING RESULTS
Effective stress relieving due to tempering- before (left) & after (right) -
Von Mises stress (MPa)
Tempering
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INTRODUCTION
SURFACE HARDENING TECHNIQUES
CASE STUDY#1 : HEAT TREATMENT OF A BEVEL GEAR
CASE STUDY#2 : INDUCTION HARDENING OF A SPUR GEA
LOCAL HEATING BY INDUCTION -> QUENCHING
CONCLUSION & PERSPECTIVES
5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
OUTLINE
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CASE STUDY#2 : STRAIGHT-CUT OR SPUR G
Typical in -use conditions with loading / unloading sequence
Alternative compression vs. tension mode at the root of the teeth
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CASE STUDY#2 : STRAIGHT-CUT OR SPUR G
How to increase the resistance to fatigue loadingfor contact fatigue : increase local hardnessfor bending fatigue : increase compressive residual stressObjective : delay cracks propagation
Mater
Resist
Yield UltimaElong
Pressu
Red =Blue
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CASE STUDY#2 : HEAT TREATEMENT SEQU
Heating (induction) TemperingQuenching (water jets)
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INDUCTION HEATING : FEM SOLVERS
Heating
Electro magnetic solver FORGE SolverHeating source
Temperature
Air
Inductor
WorkpieceOnly workpiece
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5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
INDUCTION HEATING : GLOBAL MESHING T
Heating
Generation of a unique global FEM mesh
Inductor & Part : import from CAD
Air : defined via box or cylindrical area around the inductor
The global mesh gathers all entities (air+inductor+part)
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CASE STUDY#2 : PROCESS DATA
Heating (induction)
Quenching (water jets)
Spur gear Diameter : 100mm (outer) 84mm (inner) Thickness : 10mm Alloy steel : 34CrNiMo6 (DIN 1.6582 AISI 9480)
Induction heating Current intensity : 4000 A Current frequency : from 5KHz to 20 KHz
Heating time : from 2 to 10 sec
Quenching HTC : 2600 W/C.m 2
Media temperature : room temperature Time : 15min
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CASE STUDY#2 : RESULTS
Heating (induction)
Heat power (W/m3) Magnetic field (A/m
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CASE STUDY#2 : RESULTS
Heating (induction)
Temperature (deg C) Austenite rate
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CASE STUDY#2 : RESULTS
Heating (induction)
Low frequency High frequencyHeating time is longer Heating time is shorter
Preferential heating zone: tooth base Preferential heating zone: tooth tip
= 4000 Af = 5 kHzHeating time = 10 sec
Austenite distribution Austenite distribution
Dual frequency ?
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CASE STUDY#2 : RESULTS Heating (induction) Quenching (water jets)
Martensite rateTemperature (deg C)
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CASE STUDY#2 : RESULTS Heating (induction) Quenching (water jets)
Martensite distribution - Frequency = 20000 Hz
Depth
-400
-300
-200
-100
0
100
200
300
0 0,5 1 1,5
Residual stresses (Mpa)
0
100
200
300
400
500
600
700
800
0 0,5 1 1,5
Hardness (HV)
Final material properties by the qu
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INTRODUCTION
SURFACE HARDENING TECHNIQUES
CASE STUDY#1 : HEAT TREATMENT OF A BEVEL GEAR
CASE STUDY#2 : INDUCTION HARDENING OF A SPUR GEA
CONCLUSION & PERSPECTIVES
5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
OUTLINE
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5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
CONCLUSION & PERSPECTIVES
Process simulation is the key-solution :
- Simulate the complete manufacturing process.- Associate Heat treatment & Forming operations.- Predict the final in-use properties of component.
State of the art surface hardening techniques can be simulated
- Carburizing + Quenching + Tempering.- Impact of carbon rate on IT diagram for martensitic transforma- Induction hardening (heating + quenching).- Right compromise for process parameters.
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CONCLUSION & PERSPECTIVES Extensive capabilities in FORGE NxT :
- Forming process & heat treatment simulations- Heat treatment capabilities : austenitisation, hydrogen diffusion
carburizing, quenching, tempering, - Unique electro-magnetic solver for induction heating, hardenin
heat treating,
Keep increasing our competitive advantages with :- Enhanced phase transformation models- Complementary surface treatment : nitriding, carbonitriding- Precipitate prediction incl. coupling with strain & stress
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THANK YOU
FOR YOUR ATTENTION ADDRESS:
694, av du Dr. Maurice DonatParc de Haute Technologie
06255 Mougins cedexFrance
CONTACT:+33 (0)4 9292 4200 +33 (0)4 9292 4201
marketing@transvalor.comhttp://www.transvalor.com/
5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
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