Numerical simulation of immersion quenching process of an engine cylinder head

Srinivasan, V.; Moon, Kil-Min; Chapman, David G.; Wang, De Ming; Kim, Myung-hwan

doi:10.1016/j.apm.2009.10.023

Cited by 31 publications

(16 citation statements)

References 29 publications

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“…Wang et al [ 5 ] optimized the heat treatment process route, reducing the quenching temperature to effectively reduce the axial and radial deformations of the face gear. Immersion orientations would also affect the quenching deformations of the workpieces, where the deformation of the larger end immersion is smaller than that of the smaller end immersion, which is consistent with the orientation effect observed in actual production [ 6 , 7 ]. Dybowski et al [ 8 ] optimized the heat treatment process by changing the quenching method.…”

Section: Introductionsupporting

confidence: 71%

Simulation and Experimental Verification of Die Quenching Deformation of Aviation Carburized Face Gear

et al. 2023

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The tooth width and length of face gear limit control the strength of face gear, and heat treatments are often used to improve the hardness and strength of face gear. However, heat treatments will often cause additional deformations, which will affect the dimensional accuracy of the face gear. In this paper, to effectively control the deformation and ensure the accuracy of the face gear, the finite element method was used to establish the calculation model of the face gear die quenching method, and thus, the influence of die on the gear quenching deformation was analyzed. Next, the accuracy of the calculation model was verified by the pressure quenching experiment. The results demonstrated that the inconsistent phase transformation between the surface and the center of the face gear was the key factor affecting the deformation due to the influence of the carbon content. Compared with die-less quenching, the inner hole-die can effectively limit the radial shrinkage deformation of the face gear. With the increase of the upper-die pressure, the axial and radial deformations of the face gear gradually became stable. In the actual production, the load of dies should be reasonably selected based on the gear accuracy requirements.

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Section: Introductionsupporting

confidence: 71%

Simulation and Experimental Verification of Die Quenching Deformation of Aviation Carburized Face Gear

et al. 2023

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“…The first such work was presented by Wang et al in 2002 [22] . The methodology was further developed to focus on accurate temperature prediction within the solid, as discussed by Srinivasan et al [23][24][25] [26] . Additional enhancements were made to model variable Leidenfrost temperature effects and to include additional forces acting on the vapor phase, presented by Kopun et al [27][28] .…”

Section: Modeling Water Quenching Processmentioning

confidence: 99%

An Integrated Virtual Engineering Methodology to Evaluate Manufacturing Residual Stress in Cylinder Blocks through Casting and Quenching

Jan

Swisher

Ali

et al. 2021

Heat Treating Conference

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Engine cylinder block cracking is a costly engine component failure that is often discovered late, either in the product verification phase by dynamometer testing or after product launch during vehicle operations. It is well established that the crack issues are related to the residual stress induced in the casting and heat treatment processes. To identify the quality risk in a short turn-around time and a cost-effective fashion, using computer simulations to evaluate the state of stress during casting and heat treat processes is the trend in automotive industry. In recent years, CAE methodologies have advanced significantly in both CFD and FEA to model the casting process, the quenching process, the residual stress, and the high cycle fatigue (HCF). However, calculating the final stress in the cylinder block requires several CAE software tools to work together as an integrated, streamlined engineering method and these CAE tools could be very different in meshing topologies, numerical methods, data structure, and post-processing capabilities. The intent of this research is to develop an integrated virtual engineering methodology combining casting simulation, computational fluid dynamics and finite element method to simulate the manufacturing process from the beginning of casting, through water quenching heat treatment, to engine dynamometer testing. The methodology involves three CAE tools, MAGMASOFT®, AVL FIRETM/FIRETM-M and ABAQUS, and considerable amounts of research and development work are concentrated on the validation of each individual numerical method and tools for data exchange between the software tools.

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“…As a consequence, there will be a non-homogeneous temperature distribution over the height of the component, which causes a non-homogeneous plastic deformation. Quenching processes of large components have been studied by means of models, for example, in [10,11]. Srinivasan et al [10] investigated an immersion quench process of a real automotive engine cylinder head [10].…”

Section: Introductionmentioning

confidence: 99%

“…Quenching processes of large components have been studied by means of models, for example, in [10,11]. Srinivasan et al [10] investigated an immersion quench process of a real automotive engine cylinder head [10]. Song et al [11] studied the carburization and quenching processes of a gear ring with outer diameter of approximately 250 mm [11].…”

Section: Introductionmentioning

confidence: 99%

Modeling of distortions after carburization and quenching processes of large gears

Decroos¹,

Seefeldt²

2013

Modelling Simul. Mater. Sci. Eng.

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A new finite element model is developed to predict the deformations, stresses, phase compositions and carbon concentration gradients that arise as a consequence of the physical processes involved in a carburization and quenching process of a large steel gear. Firstly, the diffusion of carbon at elevated temperatures in the austenitic range is studied in a diffusion model. Secondly, the calculated carbon concentration distribution is used as an input for a model that couples the thermal, metallographic and mechanical effects during the quenching process and calculates the evolution of the temperature, phase composition and deformation history at any point in the gear. Two effects typical for oil quenching of large gears are incorporated in the model. The first is the influence of the gear's own weight while hanging on chains before, during and after entering the quench bath. The second is the three-dimensional effect that it takes time between the moment the gear enters the oil quenching bath and the moment when the gear is fully immersed. The non-uniform temperature distribution over the gear's axis causes a non-homogeneous plastic deformation. A diffusion-thermo-metallo-mechanical model that takes these effects into account is compared with a model that does not. The results show that these effects should be incorporated.

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Numerical simulation of immersion quenching process of an engine cylinder head

Cited by 31 publications

References 29 publications

Simulation and Experimental Verification of Die Quenching Deformation of Aviation Carburized Face Gear

Simulation and Experimental Verification of Die Quenching Deformation of Aviation Carburized Face Gear

An Integrated Virtual Engineering Methodology to Evaluate Manufacturing Residual Stress in Cylinder Blocks through Casting and Quenching

Modeling of distortions after carburization and quenching processes of large gears

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