FORGE Simulation Surface Hardening Techniques

FEM SIMULATION OF SURFACE HARDENING TECHNIQUES
- APPLICATIONS TO GEAR COMPONENTS -

R.DUCLOUX 1 , S. ANDRIETTI 1 , J. BARLIER 1
1 TRANSVALOR SA - FRANCE
5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014
OUTLINE
 INTRODUCTION
 SURFACE HARDENING TECHNIQUES
 CASE STUDY#1 : HEAT TREATMENT OF A BEVEL GEAR
 CASE STUDY#2 : INDUCTION HARDENING OF A SPUR GEAR
 CONCLUSION & PERSPECTIVES

INTRODUCTION
 Standard goals of forming process simulations
- Understand material flow : underfilling, folds & laps
- Determine optimum forming sequence : reduce design cycle
- Predict material properties : grain flow, microstructure
- Extend die life : stress analysis, wear, load, …
Productivity, Quality, Innovation & Savings

INTRODUCTION
 Recent challenges
- Predict the ‘in-use’ properties of the forgings
- Simulate the entire manufacturing process including all pre & post-
forming operations (from initial heating to final heat treatment)
 Today’s presentation
- Illustrate a wide range of heat treatment simulations
- Application to surface hardening on forged components

OUTLINE
 INTRODUCTION

SURFACE HARDENING TECHNIQUES
 Goal of surface (or case) hardening
- Increase wear resistance and surface hardness
- Keep inner metal softer
- Applicable to low carbon & alloy steel
- Followed by heat treatment to get desired hardness
- Typical parts are : pinion, camshaft, gear, …
 Among the most common techniques
- Carburizing
- Nitriding, other diffusion processes
- Induction hardening
- Shot peening 5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

Source : http://www.yourdictionary.com/bevel-gear
Source : http://science.howstuffworks.com/transport/engines-equipment/gear2.htm
Source : http://science.howstuffworks.com/transport/engines-equipment/gear4.htm
 Application of surface hardening on gear components

 Very located and non-constant contact area
 Need to increase hardness on the surface
 Need to maintain ductility in the core of the component
OUTLINE
 INTRODUCTION
• CARBURIZING -> QUENCHING -> TEMPERING
CASE STUDY#1 : AUTOMOTIVE BEVEL GEAR
 Complete forming sequence description

 Two warm forging stages
 Piercing-Flash trimming, Machining
 Heat treatment operations (carburizing-quenching-tempering)
CASE STUDY#1 : PROCESS DATA
• Automotive bevel gear
– Max outer diameter ~ 52 mm
– Weight ~ 180 g
– Low carbon steel for carburizing (e.g. 20MnCr5)
• Carburizing conditions
– Process : 2h40 at 850°C
– Initial carbon rate in the part : 0.20%
– Atmosphere enriched in carbon : 0.8%
• Quenching
– Oil bath : 20°C during 2min
– HTC : 5500 W/°C.m2
• Tempering
– To relieve internal stresses : 200°C during 40min
CASE STUDY#1 : CARBURIZING STAGE
0.80% carbon
~
High
quenchability from 0.20% to 0.8% of C
0.20% carbon
~
Low
quenchability
 Objectives of the carburizing stage

 Increase of carbon concentration on surface Isothermal diagram is shifted according to the carbon rate
 Increase quenchability for low carbon steel

CASE STUDY#1 : CARBURIZING RESULTS
Carburizing
Carbon concentration (%)

after carburizing

CASE STUDY#1 : QUENCHING RESULTS
Phase distribution after oil quenching Residual stress distribution

(martensite-bainite-pearlite-ferrite) (1st principal stress)

CASE STUDY#1 : PART DISTORTION
Quenching
Distortion observed on the component after quenching due to plastic deformation

(magnification x10)

CASE STUDY#1 : TEMPERING RESULTS
Tempering
Von Mises stress (MPa)
Effective stress relieving due to tempering

- before (left) & after (right) -

OUTLINE
 INTRODUCTION
• LOCAL HEATING BY INDUCTION -> QUENCHING
CASE STUDY#2 : STRAIGHT-CUT OR SPUR GEAR
Typical ‘in-use’ conditions with loading / unloading sequence
Alternative ‘compression vs. tension’ mode at the root of the teeth

CASE STUDY#2 : STRAIGHT-CUT OR SPUR GEAR
Pressure distribution
Red => compression

Blue => tension
Material characteristics
Resisting torque = 1000 N.m

Yield stress = 600 Mpa
Ultimate stress = 800 Mpa
Elongation at break = 5 %
 How to increase the resistance to fatigue loading

 for contact fatigue : increase local hardness
 for bending fatigue : increase compressive residual stress
 Objective : delay cracks propagation
CASE STUDY#2 : HEAT TREATEMENT SEQUENCE
Heating (induction) Quenching (water jets) Tempering (induction)

INDUCTION HEATING : FEM SOLVERS
Heating
Heating source
Electro magnetic solver FORGE® Solver
Temperature
Air
Inductor
Workpiece
Only workpiece

INDUCTION HEATING : GLOBAL MESHING TECHNIQUE
Heating
 Generation of a unique ‘global’ FEM mesh
 Inductor & Part : import from CAD
 Air : defined via box or cylindrical area around the inductor
 The global mesh gathers all entities (air+inductor+part)

CASE STUDY#2 : PROCESS DATA
• Spur gear
– Diameter : 100mm (outer) – 84mm (inner)
– Thickness : 10mm
– Alloy steel : 34CrNiMo6 (DIN 1.6582 – AISI 9480)
• Induction heating
Heating (induction) – Current intensity : 4000 A
– Current frequency : from 5KHz to 20 KHz
– Heating time : from 2 to 10 sec
Quenching (water jets) • Quenching

– HTC : 2600 W/°C.m2
– Media temperature : room temperature
– Time : 15min
CASE STUDY#2 : RESULTS
Heating (induction)
Heat power (W/m3) Magnetic field (A/m)

Heating (induction)
Temperature (deg C) Austenite rate

Heating (induction)
Low frequency High frequency

Heating time is longer Heating time is shorter
Preferential heating zone: tooth base Preferential heating zone: tooth tip
𝑰𝒓𝒎𝒔 = 4000 A Dual frequency ? 𝑰𝒓𝒎𝒔 = 4000 A

f = 5 kHz f = 20 kHz
Heating time = 10 sec Heating time = 2 sec
Austenite distribution Austenite distribution

Heating (induction) Quenching (water jets)
Temperature (deg C) Martensite rate

Heating (induction) Quenching (water jets)
800
Hardness (HV)
700
600
500
400
300
200
100
Depth
0
0 0,5 1 1,5 2 2,5 3
300
Residual stresses (Mpa) 𝒕𝒆𝒏𝒔𝒊𝒐𝒏
200
100
0
0 0,5 1 1,5 2 2,5 3
-100
Depth Depth
-200
-300
𝒄𝒐𝒎𝒑𝒓𝒆𝒔𝒔𝒊𝒐𝒏
-400
Martensite distribution - Frequency = 20000 Hz Final material properties by the quenching end
OUTLINE
 INTRODUCTION

CONCLUSION & PERSPECTIVES
 Process simulation is the key-solution :
- Simulate the complete manufacturing process.
- Associate Heat treatment & Forming operations.
- Predict the final ‘in-use’ properties of component.
 ‘State of the art’ surface hardening techniques can be simulated :

- Carburizing + Quenching + Tempering.
- Impact of carbon rate on IT diagram for martensitic transformation.
- Induction hardening (heating + quenching).
- Right compromise for process parameters.
CONCLUSION & PERSPECTIVES
 Extensive capabilities in FORGE® NxT :
- Forming process & heat treatment simulations
- Heat treatment capabilities : austenitisation, hydrogen diffusion,
carburizing, quenching, tempering, …
- Unique electro-magnetic solver for induction heating, hardening,
heat treating, …
 Keep increasing our competitive advantages with :
- Enhanced phase transformation models
- Complementary surface treatment : nitriding, carbonitriding
- Precipitate prediction incl. coupling with strain & stress
THANK YOU
FOR YOUR ATTENTION
ADDRESS:
694, av du Dr. Maurice Donat
Parc de Haute Technologie
06255 Mougins cedex
France
CONTACT:
+33 (0)4 9292 4200
 +33 (0)4 9292 4201
 marketing@transvalor.com
http://www.transvalor.com/

FORGE Simulation Surface Hardening Techniques

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FEM SIMULATION OF SURFACE HARDENING TECHNIQUES

- APPLICATIONS TO GEAR COMPONENTS -

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

Productivity, Quality, Innovation & Savings

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

 Application of surface hardening on gear components

 Complete forming sequence description

 Objectives of the carburizing stage

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

Carbon concentration (%)

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

Phase distribution after oil quenching Residual stress distribution

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

Distortion observed on the component after quenching due to plastic deformation

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

Von Mises stress (MPa)

Effective stress relieving due to tempering

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

Typical ‘in-use’ conditions with loading / unloading sequence

Alternative ‘compression vs. tension’ mode at the root of the teeth

Red => compression

Resisting torque = 1000 N.m

 How to increase the resistance to fatigue loading

Heating (induction) Quenching (water jets) Tempering (induction)

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

 Inductor & Part : import from CAD

 Air : defined via box or cylindrical area around the inductor

 The global mesh gathers all entities (air+inductor+part)

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

Quenching (water jets) • Quenching

Heat power (W/m3) Magnetic field (A/m)

Temperature (deg C) Austenite rate

Low frequency High frequency

𝑰𝒓𝒎𝒔 = 4000 A Dual frequency ? 𝑰𝒓𝒎𝒔 = 4000 A

Austenite distribution Austenite distribution

Temperature (deg C) Martensite rate

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

 ‘State of the art’ surface hardening techniques can be simulated :

5th Asia Forge Meeting - Kaohsiung (Taiwan) - November 3-6, 2014

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