热处理工艺设计-元分析软件课件

热处热处理工理工艺设计艺设计有限元分析有限元分析软软件件Copyright DCT Inc.2010热处理工艺设计Copyright DCT Inc.2010DANTE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DANTE是以有限元为基础的热处理工艺模拟商业化软件.DAN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模拟分析结果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 怎样应用DANTE节约制造成本、提高设计质量？通过软件来“CAD&Model BuildingDANTE 模拟分析方法微观组织变形残余应力CAD&Model BuildingDANTE 模拟分DANTE 模拟的典型零件DANTE 模拟的典型零件DANTE 软件的结构DANTE:user subroutines link to ABAQUS/STANDARDABAQUS/CAE is used for model buildingABAQUS/Standard is the solverABAQUS/Viewer is used for postprocessing resultsDANTE Installation DirectoryDANTE Database of Steels:mechanical,thermal and phase transformation data files Low and medium carbon steels Low and medium alloy carburizing steels Low and medium alloy through-hardening steelsDANTE Heat Transfer Database Furnace Heating Data Oil Quenching Data Salt Quenching Data Gas Quenching Data Spray Quenching Data Air Cooling DataDANTE HELP SystemDANTE SubroutinesDANTE 软件的结构DANTE:user subr零件热处理模拟分析例子和验证零件热处理模拟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(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 elements2D,Axisymmetric ModelRing with Center HubAISI 5120 齿轮坯油淬火工艺模拟 油淬火的程序:2D渗碳过程Microprobevs.Simulation渗碳过程MicroprobeAISI 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AISI 5120 齿轮坯渗碳和油淬火后变形预测AISI 5120 齿轮坯渗碳和油淬火后变形预测Comparison of Predicted&Residual Stress Profiles Calculated from X-RAY and Neutron Diffraction Tests for 5160 Quenched Steel BarsOil Quenched&TemperedIntensively Quenched&Tempered圆柱件淬火回火后残余应力Comparison of Predicted&ResiAISI 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AISI 1045 Steel 带导向槽轴形件模拟结果和实验曲轴件热处理模拟During Cooling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:温度曲轴热处理模拟:奥氏体曲轴热处理模拟:奥氏体曲轴热处理模拟:切开面奥氏体曲轴热处理模拟:切开面奥氏体曲轴热处理模拟:变形预测曲轴热处理模拟: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米材料:300M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米飞机起落架淬火过程中的温度场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温度场变速器输出轴热处理过程中的应力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 failureSchematic of Test Fixturing单齿疲劳强度试验10:1 maximum to minimum load r单齿疲劳强度试验数据:Benefit of REM单齿疲劳强度试验数据:Benefit of REMIQ800 MPa120 ksiOQ1000 MPa148 ksiStress Free1600 MPa232 ksiStress State in Test Gear at 1400 lbs.Bending LoadMPa单齿疲劳载荷下齿轮应力分布IQOQStress FreeStress State inAISI 4150Oil QuenchAISI 9310Carburization+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AISI 4150AISI 9310齿轮设计过程中考虑材料选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:原设计齿轮动态疲劳测试应力重新分布:优化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:温度和奥氏体斜锥齿轮淬火模拟:最大最小主应力斜锥齿轮淬火模拟:最大最小主应力油孔周围的温度场分布不均匀汽车曲轴件感应淬火过程模拟:感应加热3.0秒后的温度场油孔周围的温度场分布不均匀汽车曲轴件感应淬火过程模拟: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秒后奥氏体分布奥氏体层大概 2.5 mm汽车曲轴件感应淬火过程模拟: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汽车曲轴件感应淬火过程模拟: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脱碳后的碳分布齿轮热处理过程中表面脱碳模拟About 0.5 mm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.About 0.5 mm表面脱碳对残余应力及淬火裂纹的影响预3D 单齿模型端面齿轮模压淬火过程模拟3D 单齿模型端面齿轮模压淬火过程模拟Axial Displacement After Press Quench with Load Still Applied contour 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 Removed tooth section lifts approximately 2.3 mm(0.090”)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.)Axial Displacement After Press0.065”springbackWithout ShimmingWith Shimming端面齿轮模压淬火过程模拟(cont.)0.065”springbackWithout Shimm端面齿轮模压淬火后预测的残余应力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过程模拟3D 单齿模型环形齿轮模压淬火后的变形环形齿轮模压淬火后的变形Scenario 445 seconds air transfer100 seconds dwellScenario 6120 seconds air transfer20 seconds dwellScenario 545 seconds air transfer20 seconds dwell加载前下模对齿轮冷却的影响Scenario 4Scenario 6Scenario 5热处理后残余应力预测热处理后残余应力预测Unit:MPaPress Quench Scenario 4热处理后齿轮加工过程中的变形Unit:MPaPress Quench ScenarioDANTE 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DANTE 模型和数据库利用热电偶数据反求热边界条件利用热电偶数据反求热边界条件Data AcquisitionTime temperature data from thermocouplesData Analysis-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.)Data Acquisition利用热电偶数据反求热边界条件碳扩散模型Establishes carbon profile within the component during carburizationMass diffusion model is appliedModeling furnace gas carburizing processes Surface carbon potential following time dependent curve based on a rise to equilibrium carbon levelModeling vacuum carburizing processesSurface carbon flux in terms of the carburizing schedule碳扩散模型Establishes carbon profilCustom kinetics model:Kinetics based on dilatometry dataKinetics based on TTT curvesKinetics based on CCT curvesKinetics based on Jominy dataGlobal kinetics model:The user inputs the chemistry to calculate phase volumes based on cooling path,or to calculate Jominy hardnessDANTE kinetics predict:Volume fractions of ferrite,pearlite,bainite,and martensite throughout an arbitrary cooling pathKinetics verification:-Run DANTE dilatometry model,and compare with the experiments -Run DANTE utilities to obtain TTT(CCT)curves,and compare with references-Run DANTE Jominy endquench model,and compare with experiments相变模型及参数确定Custom kinetics model:相变模型及参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 CheckingFitting ToleranceDilatometry FittingTTT Fitting相变模型参数的拟合方法Jominy CheckingFitting ToleranDANTE 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 phasesAccounts for transformation induced plasticityEffectively calculates the material response during loading,unloading,and reverse loading*DANTE uses the IR100 Award winning BCJ Material Model developed at Sandia National LaboratoryDANTE 力学模型Defines mechanical 利用传统应力-应变数据拟合力学模型参数利用传统应力-应变数据拟合Phase Transformation Kinetics Fitting for Heating&CoolingUses dilatometry dataUses TTT&CCT or CHT dataUses Jominy data(cooling)TTT,CCT,and Jominy Diagram Generator Mechanical Parameters FittingUses temperature dependent compression and tension test dataHeat Transfer Coefficient DeterminationUses thermocouple data DANTE/GCARB for Gas Carburization Process Design(Time,Temperature,and Carbon Potential)DANTE/VCARB for Vacuum Carburization Boost/Diffuse Schedule Design.DANTE 附属工具Phase Transformation Kinetics DANTE 软件购买选择 Annual Licensing(Seat)-Perpetual Software Licensing with Maintenance Agreement-Training&Trial License-Tools&UtilitiesMechanical Data FittingKinetics Fitting Jominy Hardness PredictorDANTE 软件购买选择-Annual LicensDeformation Control Technology,Inc.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 AgreementTraining&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 Deformation Control Technology联联系方式系方式:Deformation Control Technology,Inc.7263 Engle Road,Suite 105,Cleveland,Ohio,USAPhone:(440)234-8477Fax:(440)234-9140E-mail:supportDeformationCWebsite:www.DeformationC联系方式: