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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 确定造成热处理变形、缺陷等问题
2、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(5 min.):132 C空冷至室温齿轮坯的尺寸:ID=
3、35 mmOD=57 mmHeight=22 mm轴对称网格:380 elements,2D,Axisymmetric Model,Ring with Center Hub,渗碳过程,Microprobevs.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 Calculated from X-RAY and Neutron Diffraction Tests fo
4、r 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
5、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,IQ800 MPa120 ksi,OQ1000 MPa148 ksi,Stress Free1600 MPa232 ksi,Stress State in Test Gear
6、 at 1400 lbs.Bending Load,MPa,单齿疲劳载荷下齿轮应力分布,AISI 4150Oil Quench,AISI 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,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 2.5 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
7、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 Load Still Applied contour plot shows the web bowing downward(red is positive i
8、n 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 140
9、F 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 445 seconds air transfer100 seconds dwell,Scenario 6120 seconds air transfer20 seconds dwell,Scenario 545 seconds air transfer20 seconds d
10、well,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 AcquisitionTime-temperature data from thermocouplesData AnalysisUsing optimization or reverse calculation to determine heat transfer coefficients,利用热电偶数据反求热边界条件(Co
11、nt.),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 car
12、bon flux in terms of the carburizing schedule,Custom 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 calcul
13、ate 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 referencesRun DAN
14、TE 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,DANTE 力学模型,Defines mechanical properties for each phase as a function of%C,T,Embedded mixture model calculates the mechanical
15、 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 Laboratory,利
16、用传统应力-应变数据拟合力学模型参数,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 De
17、terminationUses 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,DANTE 软件购买选择-Annual Licensing(Seat)-Perpetual Software Licensing with Maintenance Agreement-Training
18、&Trial License-Tools&UtilitiesMechanical Data FittingKinetics Fitting Jominy Hardness Predictor,Deformation Control Technology,Inc.provides consulting services on both heat treatment modeling and metallurgical works.Deformation Control Technology,Inc.also provides DANTE licenses.Annual Licensing(Sea
19、t).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,联系方式:Deformation Control Technology,Inc.7263 Engle Road,Suite 105,Cleveland,Ohio,USAPhone:(440)234-8477Fax:(440)234-9140E-mail:supportDeformationCWebsite:www.DeformationC,
