Optimization Based on Orthogonal Experiment Design and Numerical Simulation for Carburizing Quenching Process of Helical Gear

Abstract

Predictions of distortion and hardness after heat treatment by numerical simulation are very useful for determining the optimum condition and for controlling the distortion of machinery parts. In this article, the combination method of orthogonal experiment and numerical simulation is used to optimize the standard heat treatment condition by reducing the distortion after carburizing quenching. A helical gear made of carburizing steel 20MnCrS5 is simulated using three-dimensional coupled analysis that is based on thermo-mechanical theory. The good agreement between the experiment and simulation is verified by the comparison between the experimental data and the simulated data. Firstly, the influencing factors of distortion after carburizing quenching are investigated and discussed. Four influence factors of heat treatment are selected as follows: carburizing time, the cooling time before 860°C, the holding time at 860°C, and the gear orientation during quenching. Next, selection of the optimal case is then determined by comparing the distortions. Finally, a new optimization method of minimum distortion after carburizing quenching is provided.

Verification of the Non-Axisymmetric Deformation Mechanism of Bearing Rings after Quenched in a Multi-Field Coupled Simulation

“…External orthogonal symmetrical and internal axial symmetry heat transfer is when different heat transfer boundary conditions are applied to the two sets of orthogonal symmetrical external surfaces of the bearing outer ring, and the same heat transfer boundary condition is applied to all internal surfaces of the bearing outer ring. According to the cooling curve of the quenching oil in Figure 5, two heat transfer coefficients were set (there is a certain time difference between the two heat transfer coefficient rules), as shown in Figure 7 [4,11,21,22].…”

“…Professor Inoue and Ju put forward the phase transition mechanics theory and developed heat-treatment simulation software (COSMAP) with a multi-field coupled function, according to the theory [5]. In recent years, COSMAP has been applied to solve many types of heat-treatment engineering problems [6][7][8][9][10][11]. Xusheng Li et al simulated a steel gear model based on the measured phase-change plasticity parameters and the metal-thermal-mechanical theory.…”

Improvement and Analysis of Fatigue Strength for Mild Steel 20MnCrS5 during Carburizing and Quenching

“…1 b reduces carburization time and increases diffusion time. It is summarized from the previous optimization work it can achieve minimal distortion [18].…”

Predictions and Experiments on the Distortion of the 20Cr2Ni4A C-ring during Carburizing and Quenching Process

“…With the development of computer simulation technology, theoretical models and finite element analysis methods have gradually improved, providing new ways to control heat treatment distortion. Some scholars have used numerical simulation to conduct in-depth analysis of carburizing and quenching [5][6][7][8][9][10]. Silva et al simulated the quenching process of an AISI 4140 steel C-ring in oil, covering the analysis of the distortion caused by both thermal contraction and phase transformation [6].…”