Coupled Thermal-Multiphase Flow Analysis in Quenching Processes for Residual Stress Optimization in Compressor and Turbine Disks

2008 ◽  
Author(s):  
Marcel Springmann ◽  
Arnold Ku¨hhorn
Keyword(s):  
Heat Transfer ◽  
Residual Stress ◽  
Residual Stresses ◽  
Flow Analysis ◽  
Nucleate Boiling ◽  
Jet Engines ◽  
Simulation And Optimization ◽  
Quenching Process ◽  
Stress Optimization ◽  
Turbine Disks

The durability of compressor and turbine disks in jet engines is strongly influenced by residual stresses caused by the manufacturing process. The main goal of our work is the simulation and optimization of the heat treatment, to adjust reliably the residual stresses. After forging and drilling the disk blank is heated in a furnace. In the following quenching process the disk is cooled down in an oil bath, whereas plastic deformations occur in the disk. The coupled thermal-flow analysis is accomplished using a commercial CFD code. During the quenching process radiation, boiling and condensation of the oil as well as appropriate heat transfer mechanisms are considered. The heat transfer due to film, transition and nucleate boiling is modeled via user-defined functions. Subsequently, nonlinear residual stress calculations are performed in a commercial FEM program based on the determined temperature field.

Heat transfer coefficients for quenching process simulation

2004 ◽  
Vol 120 ◽  
pp. 269-276
Author(s):  
M. Maniruzzaman ◽  
R. D. Sisson
Keyword(s):  
Heat Transfer ◽  
Boundary Condition ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Process Simulation ◽  
Nucleate Boiling ◽  
Film Boiling ◽  
Transfer Coefficients ◽  
Heat Transfer Coefficients ◽  
Quenching Process

Quenching heat treatment in a liquid medium is a very complex heat transfer process. Heat extraction from the part surface occurs through several different heat transfer mechanisms in distinct temperature ranges, namely, film boiling, partial film boiling (i.e. transition), nucleate boiling and convection. The maximum heat transfer occurs during the nucleate boiling stage. Experimental study shows that, the effective surface heat transfer coefficient varies more than two orders of magnitude with the temperature during the quenching. For quenching process simulation, accurate prediction of the time-temperature history and microstructure evolution within the part largely depends on the accuracy of the boundary condition supplied. The heat transfer coefficient is the most important boundary condition for process simulation. This study focuses on creating a database of heat transfer coefficients for various liquid quenchant-metallic alloy combinations through experimentation using three different quench probes. This database is a web-based tool for use in quench process simulation. It provides at-a-glance information for quick and easy analysis and sets the stage for a Decision Support System (DSS) and Data Mining for heat-treating process.

Residual Stress in Plain Carbon Steel Induced by Laser Hardening

2015 ◽  
Vol 812 ◽  
pp. 321-326 ◽  
Author(s):  
A. Filep ◽  
Márton Benke ◽  
Valéria Mertinger ◽  
Gábor Buza
Keyword(s):  
Heat Transfer ◽  
Residual Stress ◽  
Residual Stresses ◽  
Plain Carbon Steel ◽  
Laser Hardening ◽  
Manufacturing Processes ◽  
Stress Profile ◽  
Multiple Sources ◽  
Residual Stress Profile ◽  
Hardening Treatment

Technological residual stresses have great importance in the manufacturing processes and the lifetime of components. The residual stresses formed by quenching can be very diverse because of its multiple sources. Alternative quenching processes such as laser hardening have a great potential for different applications. The direction of heat transfer during laser hardening is the opposite compared to conventional quenching. This further increases the complexity of the developed stress state. The residual stress profile and the microstructure formed by laser hardening treatment are investigated in the present manuscript.

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.

Effects of Heat Transfer Coefficients on Quenching Residual Stresses in 7055 Aluminum Alloy

2016 ◽  
Vol 877 ◽  
pp. 647-654 ◽  
Author(s):  
Ya Nan Li ◽  
Yong An Zhang ◽  
Xi Wu Li ◽  
Zhi Hui Li ◽  
Guo Jun Wang ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Residual Stresses ◽  
Transfer Coefficient ◽  
Transfer Coefficients ◽  
Heat Transfer Coefficients ◽  
Water Flows ◽  
Quenching Process ◽  
7055 Aluminum Alloy ◽  
The Heat Transfer Coefficient

The quenching process can produce great residual stresses in 7055 aluminum alloy plates. The main factor that affects the quenching residual stresses is the heat transfer coefficient in the quenching process. In this paper, the heat transfer coefficients of spray quenching under different spray water flows were measured by using the inverse method, and the heat transfer coefficients of immersion quenching under different water temperatures were measured by the iterative method. The heat transfer coefficient increases as the spray water flow increases while decreases as the water temperature increases. The basic differences of water temperatures/spray water flows/quenching methods are the different heat transfer coefficients. According to the heat transfer coefficients results of immersion and spray quenching, an orthogonal test was carried out to study the effects of heat transfer coefficients in different temperature regions on the quenching residual stresses. The heat transfer coefficients in the range of 100oC ~200oC have a great influence on the quenching residual stresses, especially for the heat transfer coefficient near 150oC.

Heat transfer behavior during water spray quenching of 7xxx aluminum alloy plates

2021 ◽  
pp. 1-36
Author(s):  
Ning Fan ◽  
Baiqing Xiong ◽  
Zhihui Li ◽  
Yanan Li ◽  
Xiwu Li ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Aluminum Alloy ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Nucleate Boiling ◽  
Spray Parameters ◽  
Spray Distance ◽  
Heat Transfer Behavior ◽  
Quenching Process ◽  
Transfer Behavior

Abstract The desired microstructure and mechanical properties of heat treatable 7xxx aluminum alloy can be achieved after spray quenching by controlling spray parameters. However, heat transfer behavior between specimen and quenchant is transient and complicated in quenching process. In this paper, a spray quenching system was utilized to quench for 7xxx aluminum alloy. The influence of spray parameters, including spray pressure and spray distance, on heat transfer behavior was examined and discussed. Heat flux and heat transfer coefficient were calculated by iterative method. The results indicated that the aluminum alloy experienced transition boiling, nucleate boiling and convection cooling regimes during spray quenching process. Heat transfer capability firstly increased and then decreased with the increasing of spray pressure or spray distance. A function of local heat transfer coefficient which is variable in specimen surface temperature, spray parameters and spatial location was constructed. Residual stress of 7xxx aluminum alloy plates was increased firstly and then slightly differed with the increase of volumetric flux.

Effect of Residual Stresses Caused by Thermal Treatment on Creep Crack Growth Rate in Aluminium Gas Cylinders

1998 ◽  
Author(s):  
Raafat Ibrahim ◽  
Dmitry Ischenko
Keyword(s):  
Residual Stress ◽  
Growth Rate ◽  
Residual Stresses ◽  
Crack Growth ◽  
Creep Crack Growth ◽  
Stress Distributions ◽  
Creep Crack ◽  
Quenching Process ◽  
Creep Crack Growth Rate ◽  
Gas Cylinders

Abstract Aluminum gas cylinders, which are in common use for various purposes, are susceptible to creep crack growth. Residual stresses introduced during the quenching process in aluminum gas cylinders contribute to the development of cracks. This may result in leakage or fracture of the cylinders. Finite element studies were conducted to evaluate the effect of the quenching process on through thickness inelastic strain and the residual stress distributions in the neck area of gas cylinders. Numerical modeling and experimental studies confirmed that a high level of tensile residual stresses exists on the inner surface of aluminum gas cylinders’ neck which is susceptible to cracking. The relationship between the amount of residual stresses and cooling conditions was established. The obtained residual stress distributions were included in the calculation of the creep crack growth rates. It was shown that residual stresses caused by manufacturing processes have a significant effect on the creep crack growth rate.

Development of Predicted Stress and Strain during Conventional and after Mitigation of Welded Aluminium-Manganese Alloy

2013 ◽  
Vol 762 ◽  
pp. 596-601
Author(s):  
F. Soul ◽  
M. Ateeg
Keyword(s):  
Heat Transfer ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Thermal Stresses ◽  
Stress And Strain ◽  
Manganese Alloy ◽  
Element Analysis ◽  
Longitudinal Residual Stress ◽  
Mitigation Technique

The trend in automotive, aircraft, and marine industries is the increasing use of sheet materials to reduce weight in components and optimize materials performance. Welding is the main fabrication and assembly process in many of these industrial applications. However, in using thin-shell structures in such applications, welding may results in significant residual stresses and out-of-plane distortion. Transient thermal stresses, residual stresses, and distortion sometimes cause cracking and mismatching of joints. High tensile residual stresses are undesirable since they can contribute to fatigue failure. The analysis and measurement of temperature and stresses in component are often too complex to conduct in practise, and thus finite element models provide feasible approach to examine these matters. In this paper, finite element analysis has been performed using the ANSYS package to study the behaviour of longitudinal residual stress and strain in a welded thin aluminium-manganese alloy. The model presented simulates conventional welding and welding with the introduction of welding mitigation technique for enhancement of heat transfer, in which a trailing heat sink was applied. The thermal profiles obtained using the mitigation technique is completely different from those obtained in the conventional cooling. The localized transient residual stress and through-thickness strain after applying a cooling sink are discussed. The transient residual stress behaviour was highly affected by the modified temperature distribution and magnitude due to introducing the heat transfer enhancement.

Numerical Simulation of Cr12MoV Steel during Quenching Process

2014 ◽  
Vol 989-994 ◽  
pp. 751-754
Author(s):  
Wei Zhang ◽  
Zhou De Qu ◽  
Xiao Hu Deng ◽  
Xing Wang Duan
Keyword(s):  
Heat Transfer ◽  
Numerical Simulation ◽  
Residual Stress ◽  
Finite Element ◽  
Heat Transfer Coefficient ◽  
Surface Heat ◽  
Finite Element Software ◽  
Quenching Process ◽  
Surface Heat Transfer Coefficient ◽  
Nonlinear Surface

The excessive residual stress induced by quenching in steels will easily result in distortion and failure of parts. In order to obtain the more suitable quenchant, quenching process of Cr12MoV steel with different mediums involving water and oil are simulated, respectively. In present paper, the influence of nonlinear surface heat transfer coefficient, thermodynamic parameters and latent heat are considered comprehensively. The distribution of temperature, microstructure, hardness and residual stress after quenching for Cr12MoV steel are simulated by DEFORM finite element software. According to the results mentioned above, the variations of each field of the steel are analyzed.

Simulation of Quenching in Aluminium and Comparison With Neutron Diffraction Measurements

2008 ◽  
Author(s):  
R. J. Dennis ◽  
S. Phillips ◽  
C. E. Truman ◽  
A. Stiles ◽  
R. Plant
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Finite Element ◽  
Neutron Diffraction ◽  
Residual Stresses ◽  
Finite Element Methods ◽  
Test Specimen ◽  
Internal Diameter ◽  
Linear Finite Element ◽  
Quenching Process

The through life integrity of engineering components are routinely assessed using complex finite element methods. A critical input to such an assessment is an understanding of the operating environment, including service loading and temperature. Significant effort is expended identifying and understanding the effect of service loads on component integrity however there are many cases where service loading in isolation cannot account for premature failure of components during testing or in-service. A key assumption is that components in the as-built condition are often treated as stress and defect free and of nominal dimensions. This approach can however be inadequate and there are many documented cases where residual stress has influenced the in-service integrity of components. In this paper the magnitude and distribution of residual stresses are investigated in a quenched Aluminium 2014A TB test specimen. The test specimen has been specifically designed to contain design features representative of pressurised aerospace components which are quenched during manufacture. The specimen has two sections, one cylindrical (65mm internal diameter) and one oval (125mm largest internal diameter). The outer wall thickness is 10mm and the overall specimen length is 200mm with the two sections joined by a 30mm bridge section. The specimen has been subject to solution heat treatment at 505°C for five hours. Following heat treatment the specimen is rapidly quenched in cold water at 10°C with the cylindrical end entering the water first. Non-linear finite element methods have been developed to simulate the quenching process making use of user defined subroutines to enhance the standard features available in the finite element code. The accuracy of the predicted residual stresses has been assessed by comparison with neutron diffraction measurements at a range of critical locations. The work provides an extremely useful insight into how non-linear finite element methods can be successfully used to predict the residual stresses that are generated as a result of the quenching process. Where residual stresses are a potential integrity concern an understanding of the magnitude and spatial distribution of residual stress can be used to influence both the design and in-service operation of components.

Heat transfer coefficients for quenching process simulation

2004 ◽  
Vol 120 ◽  
pp. 521-528
Author(s):  
M. Maniruzzaman ◽  
R. D. Sisson
Keyword(s):  
Heat Transfer ◽  
Boundary Condition ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Process Simulation ◽  
Nucleate Boiling ◽  
Film Boiling ◽  
Transfer Coefficients ◽  
Heat Transfer Coefficients ◽  
Quenching Process

Quenching heat treatment in a liquid medium is a very complex heat transfer process. Heat extraction from the part surface occurs through several different heat transfer mechanisms in distinct temperature ranges, namely, film boiling, partial film boiling (i.e. transition), nucleate boiling and convection. The maximum heat transfer occurs during the nucleate boiling stage. Experimental study shows that, the effective surface heat transfer coefficient varies more than two orders of magnitude with the temperature during the quenching. For quenching process simulation, accurate prediction of the time-temperature history and microstructure evolution within the part largely depends on the accuracy of the boundary condition supplied. The heat transfer coefficient is the most important boundary condition for process simulation. This study focuses on creating a database of heat transfer coefficients for various liquid quenchant-metallic alloy combinations through experimentation using three different quench probes. This database is a web-based tool for use in quench process simulation. It provides at-a-glance information for quick and easy analysis and sets the stage for a Decision Support System (DSS) and Data Mining for heat-treating process.

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