Simulation of carburizing-quenching of a gear. Effect of carbon content on residual stresses and distortion

2004 ◽  
Vol 120 ◽  
pp. 489-497
Author(s):  
R. Mukai ◽  
D.-Y. Ju
Keyword(s):  
Residual Stress ◽  
Phase Transformation ◽  
Carbon Steel ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Helical Gear ◽  
Coupled Analysis ◽  
Transformation Plasticity ◽  
Quenching Process ◽  
Thermal Physical Properties

Predictions of deformation, residual stresses and hardness after heat treatment of gears by numerical simulation are very useful to determine optimum condition to decrease the distortion of machinery parts. In this paper, simulation on carburizing quenching of a helical gear made of carbon steel SCr420 was carried out using three-dimensional coupled analysis based on thermo-mechanical theory considering phase transformation. The expansion and latent heat due to phase transformation at various carburizing conditions were measured by TMA and DSC to determine the thermal physical properties of SCr420 carbon steel. The influence of the transformation plasticity strain on deformation, residual stress and hardness of a gear was clarified in the simulation. The accuracy of simulation also is verified by the comparison between the experimental data and the simulated result of the distortion and residual stress. From the predicted results, improvement of the hardness and strength on surface of the gear due to the carburizing-quenching process can be verified.

Modeling and Experimental Verification of Plastic Behavior of the Martensitic Transformation Plastic Behavior in a Carbon Steel

2006 ◽  
Vol 118 ◽  
pp. 369-374 ◽  
Author(s):  
Dong Ying Ju ◽  
Wei Min Zhang ◽  
Y. Matsumoto ◽  
Ryuji Mukai
Keyword(s):  
Phase Transformation ◽  
Carbon Steel ◽  
Martensitic Transformation ◽  
Computational Simulation ◽  
Carbon Steels ◽  
Phase Transformation Temperature ◽  
Plastic Behavior ◽  
Measured Temperature ◽  
Transformation Plasticity ◽  
Quenching Process

The objective of this paper is to extend the capability of analyzing the time dependence and coupling of temperature, stress and strain effects on the macroscopic and microscopic structures subjected to quenching, and to introduce a theory of the kinetic of the phase transformation. Strain due to phase transformation, transformation plasticity and thermal expansion are the dominant factors that need to be included in the simulation of a quenching process. The evolution of the microstructure also influences the constitutive equations. In particular, as the temperature changes from the high to phase transformation, temperature and then room temperature, the stress-strain relationship changes from elastic-plastic strain. Therefore, in order to obtain a high strength and ductility in carbon steels, transformation plasticity often has a major effect in increasing of the residual stress during quenching process. In this paper, we measured temperature change and distortion occurring during the quenching process of a carbon steel(SCr420) by thermal simulation machine (Gleeble 1500) are used to determine the parameter of transformation plasticity due to the generation of martensite. The modeling of martensitic transformation plasticity is also verified by using of computational simulation of the quenching process.

Effect of Residual Stress or Plastic Deformation History on Fatigue Life Simulation of Pipeline Dents

2018 ◽  
Author(s):  
Xian-Kui Zhu ◽  
Rick Wang
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Strain History ◽  
Deformation History ◽  
Stress Strain ◽  
Element Analysis ◽  
Fea Model

Mechanical dents often occur in transmission pipelines, and are recognized as one of major threats to pipeline integrity because of the potential fatigue failure due to cyclic pressures. With matured in-line-inspection (ILI) technology, mechanical dents can be identified from the ILI runs. Based on ILI measured dent profiles, finite element analysis (FEA) is commonly used to simulate stresses and strains in a dent, and to predict fatigue life of the dented pipeline. However, the dent profile defined by ILI data is a purely geometric shape without residual stresses nor plastic deformation history, and is different from its actual dent that contains residual stresses/strains due to dent creation and re-rounding. As a result, the FEA results of an ILI dent may not represent those of the actual dent, and may lead to inaccurate or incorrect results. To investigate the effect of residual stress or plastic deformation history on mechanics responses and fatigue life of an actual dent, three dent models are considered in this paper: (a) a true dent with residual stresses and dent formation history, (b) a purely geometric dent having the true dent profile with all stress/strain history removed from it, and (c) a purely geometric dent having an ILI defined dent profile with all stress/strain history removed from it. Using a three-dimensional FEA model, those three dents are simulated in the elastic-plastic conditions. The FEA results showed that the two geometric dents determine significantly different stresses and strains in comparison to those in the true dent, and overpredict the fatigue life or burst pressure of the true dent. On this basis, suggestions are made on how to use the ILI data to predict the dent fatigue life.

Residual Stress Analysis Considering Phase Transformation and Transformation Plasticity for Heat-Treated Large Size Shaft

2016 ◽  
Vol 725 ◽  
pp. 647-652 ◽  
Author(s):  
Yusuke Yanagisawa ◽  
Yasuhiro Kishi ◽  
Katsuhiko Sasaki
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Phase Transformation ◽  
Air Cooling ◽  
Water Cooling ◽  
Stress Distributions ◽  
Transformation Plasticity ◽  
Large Size ◽  
Heat Treated ◽  
Good Agreement

The residual stress distributions of the forgings after both water-cooling and air-cooling were measured experimentally. The residual stress occurring during the heat-treatment was also simulated considering the phase transformation and the transformation plasticity. A comparison of the experiments with the simulations showed a good agreement. These results shows that the transformation plastic strain plays an important role in the heat treatment of large forged shafts.

Residual Stresses in Steel and Zirconium Weldments

1997 ◽  
Vol 119 (2) ◽  
pp. 137-141 ◽  
Author(s):  
J. H. Root ◽  
C. E. Coleman ◽  
J. W. Bowden ◽  
M. Hayashi
Keyword(s):  
Residual Stress ◽  
Electron Beam ◽  
Neutron Diffraction ◽  
Residual Stresses ◽  
Prolonged Exposure ◽  
Electron Beam Welding ◽  
Three Dimensional ◽  
Diffraction Method ◽  
Outer Diameter ◽  
Stress Relieving

Three-dimensional scans of residual stress within intact weldments provide insight into the consequences of various welding techniques and stress-relieving procedures. The neutron diffraction method for nondestructive evaluation of residual stresses has been applied to a circumferential weld in a ferritic steel pipe of outer diameter 114 mm and thickness 8.6 mm. The maximum tensile stresses, 250 MPa in the hoop direction, are found at mid-thickness of the fusion zone. The residual stresses approach zero within 20 mm from the weld center. The residual stresses caused by welding zirconium alloy components are partially to blame for failures due to delayed hydride cracking. Neutron diffraction measurements in a GTA-welded Zr-2.5Nb plate have shown that heat treatment at 530°C for 1 h reduces the longitudinal residual strain by 60 percent. Neutron diffraction has also been used to scan the residual stresses near circumferential electron beam welds in irradiated and unirradiated Zr-2.5Nb pressure tubes. The residual stresses due to electron beam welding appear to be lower than 130 MPa, even in the as-welded state. No significant changes occur in the residual stress pattern of the electron-beam welded tube, during a prolonged exposure to thermal neutrons and the temperatures typical of an operating nuclear reactor.

Fast Three-Dimensional Finite Element Analysis of Weld Overlay Application on a Formed Feeder Elbow

2011 ◽  
Author(s):  
Francis H. Ku ◽  
Pete C. Riccardella
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Nuclear Reactor ◽  
Three Dimensional ◽  
Fe Method ◽  
Element Analysis ◽  
Weld Overlay ◽  
Welding Processes

This paper presents a fast finite element analysis (FEA) model to efficiently predict the residual stresses in a feeder elbow in a CANDU nuclear reactor coolant system throughout the various stages of the manufacturing and welding processes, including elbow forming, Grayloc hub weld, and weld overlay application. The finite element (FE) method employs optimized FEA procedure along with three-dimensional (3-D) elastic-plastic technology and large deformation capability to predict the residual stresses due to the feeder forming and various welding processes. The results demonstrate that the fast FEA method captures the residual stress trends with acceptable accuracy and, hence, provides an efficient and practical tool for performing complicated parametric 3-D weld residual stress studies.

scholarly journals Three-dimensional finite element simulation of residual stresses in UIC60 rails during the quenching process

2017 ◽  
Vol 21 (3) ◽  
pp. 1301-1307 ◽  
Author(s):  
Nejad Masoudi ◽  
Mahmoud Shariati ◽  
Khalil Farhangdoost
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Initial Conditions ◽  
Three Dimensional ◽  
Analysis Model ◽  
Element Analysis ◽  
Quenching Process ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

The aim of this paper is to develop means to predict accurately the residual stresses due to quenching process of an UIC60 rail. A 3-D non-linear stress analysis model has been applied to estimate stress fields of an UIC60 rail in the quenching process. A cooling mechanism with water spray is simulated applying the elastic-plastic finite element analysis for the rail. The 3-D finite element analysis results of the studies presented in this paper are needed to describe the initial conditions for analyses of how the service conditions may act to change the as-manufactured stress field.

scholarly journals Technology of Plasticity. Three-Dimensional FEM Analysis of Helical Gear Subjected to the Carburized Quenching Process.

2001 ◽  
Vol 50 (6) ◽  
pp. 598-605 ◽  
Author(s):  
Manabu FUKUMOTO ◽  
Masatoshi YOSHIZAKI ◽  
Hideki IMATAKA ◽  
Kazuo OKAMURA ◽  
Kenji YAMAMOTO
Keyword(s):  
Three Dimensional ◽  
Fem Analysis ◽  
Helical Gear ◽  
Quenching Process

Simple Benchmark Problems for Finite Element Weld Residual Stress Simulation

2013 ◽  
Author(s):  
Mike C. Smith ◽  
Steve Bate ◽  
P. John Bouchard
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Phase Transformation ◽  
Solid State ◽  
Residual Stresses ◽  
Benchmark Problems ◽  
Transient Temperature ◽  
Beam Specimen ◽  
Weld Residual Stress ◽  
Solid State Phase Transformation

Finite element methods are used increasingly to predict weld residual stresses. This is a relatively complex use of the finite element method, and it is important that its practitioners are able to demonstrate their ability to produce accurate predictions. Extensively characterised benchmark problems are a vital tool in achieving this. However, existing benchmarks are relatively complex and not suitable for analysis by novice weld modellers. This paper describes two benchmarks based upon a simple beam specimen with a single autogenous weld bead laid along its top edge. This geometry may be analysed using either 3D or 2D FE models and employing either block-dumped or moving heat source techniques. The first, simpler, benchmark is manufactured from AISI 316 steel, which does not undergo solid state phase transformation, while the second, more complex, benchmark is manufactured from SA508 Cl 3 steel, which undergoes solid state phase transformation during welding. A number of such beams were manufactured using an automated TIG process, and instrumented with thermocouples and strain gauges to record the transient temperature and strain response during welding. The resulting residual stresses were measured using diverse techniques, and showed markedly different distributions in the austenitic and ferritic beams. The paper presents the information necessary to perform and validate finite element weld residual stress simulations in both the simple austenitic beam and the more complex ferritic beam, and provides performance measures for the austenitic beam problem.

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