热处理工艺设计有限元分析软件.ppt

热处理工艺设计有限元分析软件,CopyrightDCTInc.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&ModelBuilding,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,AISI5120齿轮坯油淬火工艺模拟,油淬火的程序:奥氏体化温度:870C渗碳炉碳势:0.85%淬火油温度(5min.):132C空冷至室温齿轮坯的尺寸:ID=35mmOD=57mmHeight=22mm轴对称网格:380elements,2D,AxisymmetricModel,RingwithCenterHub,渗碳过程,Microprobevs.Simulation,AISI5120齿轮坯渗碳和油淬火后模拟预测的微观相分布(traceacrossmid-height),AISI5120齿轮坯渗碳和油淬火后变形预测,ComparisonofPredicted&ResidualStressProfilesCalculatedfromX-RAYandNeutronDiffractionTestsfor5160QuenchedSteelBars,OilQuenched&Tempered,IntensivelyQuenched&Tempered,圆柱件淬火回火后残余应力,AISI1045Steel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,DuringCooling,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,10:1maximumtominimumloadratioServohydraulictestmachineat40cpsRunoutisdefinedas107cycleswithoutfailure,SchematicofTestFixturing,单齿疲劳强度试验,单齿疲劳强度试验数据:BenefitofREM,IQ800MPa120ksi,OQ1000MPa148ksi,StressFree1600MPa232ksi,StressStateinTestGearat1400lbs.BendingLoad,MPa,单齿疲劳载荷下齿轮应力分布,AISI4150OilQuench,AISI9310Carburization+OilQuench,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2.5mm,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0.1mm.,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0.3mm.,3D单齿模型,端面齿轮模压淬火过程模拟,AxialDisplacementAfterPressQuenchwithLoadStillAppliedcontourplotshowsthewebbowingdownward(redispositiveinthedownwarddirection)thetoptoothhasexpandedupwardby0.24mm(0.009”)andthebottomtoothhasexpandeddownwardby0.02mm(0.001”),SpringbackasDieLoadisRemovedtoothsectionliftsapproximately2.3mm(0.090”)afterremovingthepressloadandfinalcoolingfromtheoiltemperatureof140Ftoroomtemperature.,3D单齿模型,端面齿轮模压淬火过程模拟(cont.),WithoutShimming,WithShimming,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,Scenario445secondsairtransfer100secondsdwell,Scenario6120secondsairtransfer20secondsdwell,Scenario545secondsairtransfer20secondsdwell,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,PressQuenchScenario4,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,DataAcquisitionTime-temperaturedatafromthermocouplesDataAnalysisUsingoptimizationorreversecalculationtodetermineheattransfercoefficients,利用热电偶数据反求热边界条件(Cont.),碳扩散模型,EstablishescarbonprofilewithinthecomponentduringcarburizationMassdiffusionmodelisappliedModelingfurnacegascarburizingprocessesSurfacecarbonpotentialfollowingtimedependentcurvebasedonarisetoequilibriumcarbonlevelModelingvacuumcarburizingprocessesSurfacecarbonfluxintermsofthecarburizingschedule,Customkineticsmodel:KineticsbasedondilatometrydataKineticsbasedonTTTcurvesKineticsbasedonCCTcurvesKineticsbasedonJominydataGlobalkineticsmodel:Theuserinputsthechemistrytocalculatephasevolumesbasedoncoolingpath,ortocalculateJominyhardnessDANTEkineticspredict:Volumefractionsofferrite,pearlite,bainite,andmartensitethroughoutanarbitrarycoolingpathKineticsverification:RunDANTEdilatometrymodel,andcomparewiththeexperimentsRunDANTEutilitiestoobtainTTT(CCT)curves,andcomparewithreferencesRunDANTEJominyend-quenchmodel,andcomparewithexperiments,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,JominyChecking,FittingTolerance,DilatometryFitting,TTTFitting,相变模型参数的拟合方法,DANTE力学模型,Definesmechanicalpropertiesforeachphaseasafunctionof%C,T,EmbeddedmixturemodelcalculatesthemechanicalbehaviorofcompositefrommechanicalbehaviorofindividualphasesAccountsfortransformationinducedplasticityEffectivelycalculatesthematerialresponseduringloading,unloading,andreverseloading,*DANTEusestheIR100AwardwinningBCJMaterialModeldevelopedatSandiaNationalLaboratory,利用传统应力-应变数据拟合力学模型参数,PhaseTransformationKineticsFittingforHeating&CoolingUsesdilatometrydataUsesTTT&CCTorCHTdataUsesJominydata(cooling)TTT,CCT,andJominyDiagramGeneratorMechanicalParametersFittingUsestemperaturedependentcompressionandtensiontestdataHeatTransferCoefficientDeterminationUsesthermocoupledataDANTE/GCARBforGasCarburizationProcessDesign(Time,Temperature,andCarbonPotential)DANTE/VCARBforVacuumCarburizationBoost/DiffuseScheduleDesign.,DANTE附属工具,DANTE软件购买选择-AnnualLicensing(Seat)-PerpetualSoftwareLicensingwithMaintenanceAgreement-Training&TrialLicense-Tools&UtilitiesMechanicalDataFittingKineticsFittingJominyHardnessPredictor,DeformationControlTechnology,Inc.providesconsultingservicesonbothheattreatmentmodelingandmetallurgicalworks.DeformationControlTechnology,Inc.alsoprovidesDANTElicenses.AnnualLicensing(Seat).PerpetualSoftwareLicensingwithMaintenanceAgreementTraining&TrialLicense.UtilitiestosupporttheDANTEsoftware,includingbothmechanicalandphasetransformationkineticsfitting.,DCT热处理模拟和咨询服务,联系方式:DeformationControlTechnology,Inc.7263EngleRoad,Suite105,Cleveland,Ohio,USAPhone:(440)234-8477Fax:(440)234-9140E-mail:supportDeformationCWebsite:www.DeformationC,