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Optimization of induction heating process for ball screw based on finite element analysis

Li Mingzhe, Chen Baofeng, Zhang Wenliang, Sun Lizhuang, Zhang Lun, Liu Junjie

Heat Treatment of Metals 2025, 50 (1): 236-242. doi:10.13251/j.issn.0254-6051.2025.01.037

Abstract （29）

PDF （4352KB）（9）

In order to optimize the induction heating process of ball screw and improve the uniformity of its surface temperature distribution, thereby improving its manufacturing precision and performance, a finite element model was constructed by means of electromagnetic simulation software to analyze the influence of different process parameters on the surface temperature distribution of the ball screw during both static and dynamic induction heating. The results show that an excessively small internal diameter of the induction coil results in a narrow gap between the workpiece and the coil, which can easily lead to overheating of the workpiece surface. Conversely, an excessively large internal diameter results in a wide gap, reducing heating efficiency and resulting in a shallow heating layer. Therefore, selecting an induction coil with an appropriate internal diameter is essential for ensuring the quality of heating. The double-turn coil demonstrates superior performance in terms of heating efficiency and temperature uniformity. Employing high voltage and an appropriate current frequency can improve heating efficiency and control the depth of heating layer. For dynamic heating, a scanning speed of 6-10 mm/s is recommended to achieve a balance between heating efficiency and process stability.

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Numerical calculation of convective heat transfer coefficient and quenching simulation of 2195 Al-Li alloy hemispherical shell

Song Kejin, Du Yue, Fu Xuesong, Kang Li, Du Baoxian, Zhou Wenlong

Heat Treatment of Metals 2025, 50 (1): 243-249. doi:10.13251/j.issn.0254-6051.2025.01.038

Abstract （25）

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By combining analytical and numerical methods, the convective heat transfer coefficient of 2195 aluminum lithium alloy hemispherical shell was approximately calculated, and the variation law of convective heat transfer coefficient with temperature under air cooling and water cooling conditions was analyzed. Using ABAQUS finite element simulation software, a thermo-mechanical coupling model was constructed, and the quenching process of the 2195 aluminum lithium alloy hemispherical shells with diameters of ø200 mm and ø100 mm was simulated by finite element method, and the stress and strain laws during the quenching process were analyzed. The results show that during the water cooling process, the heat transfer coefficient of the aluminum lithium alloy hemispherical shell increases first and then decreases with the surface temperature of the workpiece from low to high, and the peak point appears at around 175 ℃. During the air cooling process, the convective heat transfer coefficient increases with the increase of workpiece temperature. The simulation results of the quenching process indicate that stress concentration occurs at the mouth of the hemispherical shell, and plastic strain mainly occurs at the surface of the hemispherical shell mouth. The stress and strain distribution patterns of hemispherical shells with different sizes after cooling at different inlet water temperatures are similar.

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Modeling and numerical simulation of heating process for roller hearth furnace with radiant tube heating

Kong Haoran, Pang Yuhua, Gao Qiang, Li He, Sun Qi

Heat Treatment of Metals 2025, 50 (1): 250-254. doi:10.13251/j.issn.0254-6051.2025.01.039

Abstract （25）

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In order to study the heating characteristics of steel plate in the heating furnace during heating process, a high-precision computational fluid dynamics (CFD) model of the heating furnace was established by using FLUENT based on a roller hearth furnace with radiant tube heating. The heating process of the steel plate, heating temperature of 873.5 K and heating time of 135 min, was numerically simulated, and the simulation results were experimentally verified. The simulation results show that the temperature of the steel plate in heating stage rises rapidly, with a higher surface temperature, but the overall temperature of the steel plate does not show significant differences, indicating that the overall heat transfer of the steel plate is relatively uniform. The comparison between the CFD heating model results and the experimental results shows that the maximum error in the average temperature of the steel plate is only 5 K, with an error of less than 1%, indicating good consistency between the experiment and simulation.

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Numerical simulation on induction tempering of cutter ring with gradient hardness

Sun Wei

Heat Treatment of Metals 2024, 49 (12): 254-261. doi:10.13251/j.issn.0254-6051.2024.12.041

Abstract （21）

PDF （4148KB）（14）

A coupled electric-magnetic-thermal multi-physical field model for cutter ring was established based on finite element software, and induction tempering simulation was performed on cutter ring with gradient hardness. The results show that during the induction tempering process of the cutter ring, the induced current density and magnetic induction intensity gradually decrease along the radial direction of the ring, with the maximum value occurring at the center of the ring closest to the coil. From the center to the edge direction, the temperature of the ring gradually decreases. As the coil current increases, the induced current density, magnetic induction intensity, core temperature and edge temperature of the ring also increase. As the frequency of the coil current increases, the induced current density, core temperature and edge temperature of the ring also increase, but the magnetic induction intensity decreases. The maximum relative error of the radial temperature of the cutter ring obtained from the experiment and simulation is 8.1%, which verifies the accuracy of the simulation.

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Optimization and verification of heat treatment process for ZG30CrMnSiMoVTi steel based on simulation software

Zhao Shengpei, Cheng Jun, Hu Yu, Wang Chuanjie, Zhao Lingbo

Heat Treatment of Metals 2024, 49 (12): 262-267. doi:10.13251/j.issn.0254-6051.2024.12.042

Abstract （27）

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To solve the problem of insufficient plasticity and toughness in low alloy wear-resistant steel, the quenching-tempering(Q-T) process of the ZG30CrMnSiMoVTi steel was optimized and improved by means of JmatPro and ANSYS softwares. The microstructure and comprehensive properties of the tested steel under two heat treatment processes were studied by using metallographic observation, hardness, impact and tensile tests. The results show that the water-air alternating cycle controlled cooling+tempering process with water quenching time of 10 s, air quenching time of 8 s, and cycling for 3 times can be used as the optimized heat treatment process obtained from the simulation and analysis of the steel piece of 60 mm×250 mm. For the average hardness from heart to surface, there is not much difference between 49.75 HRC after Q-T treatment and 46 HRC after 3 cycles, but the hardness at different positions after 3 cycles and tempering is more uniform. Compared with the specimen treated with Q-T, the tensile strength of the specimen after 3 cycles and tempering increases from 1246.3 MPa to 1551.7 MPa, the yield strength increases from 1038.6 MPa to 1293.1 MPa, the elongation after fracture increases from 10.5% to 12.6%, and the impact absorbed energy increases from 17.7 J to 29.1 J. Compared with the Q-T treated one, the specimen with water quenching time of 10 s, air quenching time of 8 s, and three cycles + tempering has a more uniform microstructure, and its hardness distribution is more uniform, the tensile strength, yield strength and impact absorbed energy are all improved to a certain extent.

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Thermodynamic calculation of a novel nickel-based heat-resistant alloy C-HRA-3

Zhang Peng, Chen Zhengzong

Heat Treatment of Metals 2024, 49 (12): 268-273. doi:10.13251/j.issn.0254-6051.2024.12.043

Abstract （31）

PDF （3221KB）（21）

By conducting thermodynamic calculations on the changes in the content of main elements in a novel nickel-based heat-resistant alloy C-HRA-3, the possible characteristics of the second phase that might precipitate at various temperatures were analyzed. The results show that the main precipitated phases in C-HRA-3 alloy are γ' and M₂₃C₆, with a precipitation amount of approximately 3.7wt% for γ' phase and 1.11wt% for M₂₃C₆ phase at 700 ℃. The C element has a significant impact on the precipitation amount, redissolution temperature and melting point of M₂₃C₆ phase in the alloy. The effect of Co element on the precipitation phase and melting point is relatively small. The Mo element plays a decisive role in the precipitation behavior of M₆C phase. The increase in Al and Ti content will significantly increase the precipitation amount and redissolution temperature of the γ'-phase. The Nb element has no effect on the precipitation amount of γ'-phase, but has a significant impact on the proportion of Nb in the composition elements of the γ'-phase.

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Asynchronous dual-frequency induction heating of gears based on irregular coil

Liang Jianquan, Xiao Yao, Wei Yulin, Zhao Daifu, Han Yi

Heat Treatment of Metals 2024, 49 (12): 274-283. doi:10.13251/j.issn.0254-6051.2024.12.044

Abstract （28）

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Due to the shape differences between the large and small ends of bevel gears, uneven distribution of hardening layer was caused by uneven quenching temperature distribution on the surface of bevel gears during traditional single-frequency electromagnetic heating. To solve the problem, two induction heating coil structures (hood coil and profile coil) were designed, an asynchronous dual-frequency segmented iterative cyclic induction heating method for bevel gears based on profiled coil was proposed, a physical model of electric-magnetic-thermal multi-parameter coupling was constructed and verified by induction heating test. The results show that the hood coil can heat the tooth bottom of the bevel gear well, and the profile coil can profiling heat the top and surface of the gear tooth. On this basis, the simulation results of electric-magnetic-thermal multi-field coupling for asynchronous dual-frequency induction heating show that the cycle state of asynchronous dual-frequency induction heating has a large influence on the uniformity of the temperature distribution of the tooth surface of the bevel gear. When the total time of asynchronous dual-frequency induction heating is certain, with the increase of the number of iterations, it helps to avoid excessive local temperatures, and improve the uniformity of the temperature in the direction of the imitation tooth profile and tooth width, and when the iteration cycle is up to 4 times, the temperature difference in the direction of the tooth width and the tooth profile is no longer changed significantly. As the ratio of medium and high frequency induction heating time increases, the uniformity of temperature distribution on the tooth surface of the bevel gear decreases. The asynchronous dual-frequency induction heating test on the bevel gear verifies the correctness of the constructed temperature field model.

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Verification module of stabilizing treatment fixture based on finite element analysis for titanium alloy

Liu Gang, Peng Peng, Wang Xinyu, Zhang Zengguang, Cui Jing, Liao Qiyu

Heat Treatment of Metals 2024, 49 (12): 284-288. doi:10.13251/j.issn.0254-6051.2024.12.045

Abstract （27）

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Stabilizing treatment fixture for titanium alloy designed by conventional methods is thick and heavy, and the verification cycle is long. By studying the high temperature tensile and creep behavior of the TA15 titanium alloy, a finite element model of the high temperature rupture lifetime of titanium alloy was established to simulate the deformation of the fixture under high temperature loading conditions and optimize the fixture structure. The results indicate that based on the creep test results and the Allometric1 function in the data analysis software, the creep constitutive equation of the TA15 titanium alloy is ε·=7.411×10^-8σ^2.759. The ABAQUS quasi-static analysis module and the creep constitutive equation of the TA15 titanium alloy can be used for the verification of stabilizing treatment fixture, providing a basis for its optimization design.

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Numerical analysis of flow field in an atmosphere-controlled furnace under different stirring fans based on ANSYS

Shu Dongfang, Luo Cheng, Shi Lei

Heat Treatment of Metals 2024, 49 (11): 278-283. doi:10.13251/j.issn.0254-6051.2024.11.043

Abstract （39）

PDF （4846KB）（16）

Based on FEM numerical analysis, the flow field in atmosphere-controlled sealed box furnace with different stirring fans was simulated, and by using transient and steady-state methods, the flow velocity, static pressure and dynamic pressure changes inside the controlled atmosphere furnace were analyzed under the conditions of a four blade stirring fan (Fan4) and a six blade stirring fan (Fan6). The airflow path inside the Fan4 furnace is relatively uniform, and they are all located in the upper non-working area of the furnace. The airflow path inside the Fan6 furnace is prone to forming vortices, which have a significant impact on the uniformity of furnace temperature and atmosphere. The dynamic pressure cloud diagrams inside Fan4 and Fan6 furnaces are basically similar, and the difference in dynamic pressure within the working area is relatively small. The static pressure inside the Fan6 furnace is generally higher than that of Fan4, and under the same conditions, a six blade fan will cause the furnace pressure to be too high.

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Failure analysis and laser surface composite treatment of piercing plug for seamless steel pipe based on FEM simulation

Mu Jian, Wu Hebao, Zhang Xun, Li Xiaolong, He Yin, Li Jianjun

Heat Treatment of Metals 2024, 49 (9): 284-289. doi:10.13251/j.issn.0254-6051.2024.09.048

Abstract （41）

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Finite element method (FEM) was used to analyze the temperature field, stress field, and thermo-mechanical coupling field of the piercing plug, and the maximum thermo stress, maximum coupling stress, maximum surface temperature, stress concentration area, and fatigue crack type were determined. And laser cladding+high-temperature slow oxidation composite treatment was carried out on 20Cr2Ni4 steel to improve the mechanical properties and high-temperature resistance of the plug. The FEM simulation results show that the thermo-mechanical coupling stress of the plug is the vector sum of thermo tensile stress and mechanical compressive stress. The coupling stress is dropped by about 5.7% compared with the peak value of thermo stress. The value of thermo-mechanical coupling stress is mainly affected by thermo stress, and the changing trend and distribution are mainly affected by mechanical stress. the failure of the plug originates from the crack source on the inner surface under the combined action of thermo fatigue and mechanical fatigue, and propagates radially outward to form fatigue cracks on the surface. The results of laser surface composite treatment show that after laser cladding and high temperature slow oxidation treatment, the surface hardness of 20Cr2Ni4 steel can reach 494 HV0.025, the surface strengthening layer is firmly bonded to the matrix, and the content of oxygen element in the matrix is less and more evenly, which effectively improves the service life of the plug.

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Application of model-free adaptive control in heat treatment of large 12Cr2Mo1V steel

Gao Xinbo, Qin Qingliang

Heat Treatment of Metals 2024, 49 (9): 290-296. doi:10.13251/j.issn.0254-6051.2024.09.049

Abstract （42）

PDF （2685KB）（14）

For the heating and post-welding heat treatment of large-diameter thick-walled 12Cr2Mo1V steel, the medium-frequency induction heating method was adopted and the model-free adaptive control (MFAC) algorithm replacing the traditional PID algorithm was selected for temperature control. Firstly, the physical parameters of the workpiece were analyzed, and parameters such as heating frequency, coil current, and power configuration were calculated. Then, the obtained parameters were input into COMSOL software to simulate on-site conditions and perform magnetic-thermal coupled simulation analysis, validating the feasibility of the calculated data. Next, the MFAC architecture was constructed in the SIMULINK simulation platform and compared to the traditional PID method, and the two algorithms were actually applied to observe the heating effect in the field. The results show that when large workpieces are heated to the target temperature of 700 ℃, the temperature fluctuation is smaller, the stability is higher, and the uniformity is better.

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Quenching uniformity control techniques of high-pressure gas quenching for multiple large thin-wall cylindrical parts

Li Chuang, Li Qiong, Zhan Yuheng, Cong Peiwu, Lu Wenlin, Yao Jiawei, Han Yongzhen

Heat Treatment of Metals 2024, 49 (8): 204-210. doi:10.13251/j.issn.0254-6051.2024.08.036

Abstract （30）

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High-pressure gas quenching process of large thin-wall cylindrical parts under multi-piece loading conditions was investigated by establishing a suitable three-dimensional physical model and control equations. According to the numerical simulation results of the flow field and temperature field in the furnace under different loading conditions, it is found that addition of suitable deflector plate can effectively improve the flow field in the furnace, and enhance the homogeneity of the temperature field of the workpieces in condition of meeting the quenching and cooling demand, during the process of gas quenching. The method can be used to solve the non-uniform cooling problem, which exists in the gas quenching of multiple pieces at the same time. Finally, the correctness of the simulation results is verified through experiments, which provides a feasible path for the optimization of the high-pressure gas cooling system, and also provides a theoretical basis for the future improvement of the gas quenching effect of large-scale vertical vacuum gas quenching equipment.

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Numerical simulation and experimental verification on heat-flow coupling during laser cladding of 420 stainless steel

Du Maohua, Zhang Zhenxin, Bi Guijun, Cao Lichao

Heat Treatment of Metals 2024, 49 (8): 211-219. doi:10.13251/j.issn.0254-6051.2024.08.037

Abstract （26）

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Influence of the main process parameters (laser power, scanning speed, powder feeding rate) on the molten pool temperature and the geometry of single track clad layer during laser cladding on 420 stainless steel, as well as the variation of temperature, temperature gradient and flow rate at different positions of the clad layer were studied. A heat-flow coupled 3D transient numerical model for laser cladding of 420 stainless steel powder on Q235 carbon steel substrate was established to simulate the forming process of laser cladding. The buoyancy force, Darcy resistance and Marangoni effect driven by surface tension in the molten pool were considered. The apparent heat capacity method was used to consider the latent heat of the material phase transition. The arbitrary Lagrangian-Eulerian (ALE) method was used to trace the free surface of the molten pool and simulate the growth of the molten pool. The results show that the molten pool temperature increases with the increase of laser power and powder feeding rate, but decreases with the increase of scanning speed. The process parameter that has the greatest influence on the clad layer width is the laser power and when it increases from 800 W to 1000 W, the cladding width increases by 175.4051 μm. The powder feeding rate has the greatest influence on the height and depth of clad layer. The powder feeding rate increases from 1.49 g/min to 3.17 g/min, the clad layer height increases by 309.8188 μm, while the clad layer depth decreases by 152.0495 μm. Under different laser cladding process parameters, the hardness from the top to the bottom of the clad layer decreases continuously. The experimental results show that the model can accurately predict the laser cladding process with different process parameters.

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Numerical simulation of low pressure carburizing process for 20CrMnTi steel

Deng Xiaohu, Song Wenjuan, Fan Yuanyuan, Guo Jingyu, Wang Huizhen, Zhou Leyu, Xu Yueming, Ju Dongying

Heat Treatment of Metals 2024, 49 (8): 220-224. doi:10.13251/j.issn.0254-6051.2024.08.038

Abstract （51）

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Based on the principle of multiple factors such as temperature, diffusion, phase transformation and stress, finite element simulation technology was used to simulate and analyze the carburizing process of 20CrMnTi steel under low pressure environment. The simulation process fully considered the boundary condition characteristics of the alternating strong infiltration and diffusion in the low pressure carburizing process, and the strong infiltration and strong infiltration+diffusion were simulated separately, the carbon concentration, martensite volume fraction and hardness distribution were obtained. The results indicate that as the diffusion time increases, the surface carbon concentration of the specimen decreases and the depth of the carburized layer increases. The simulation results of carbon concentration distribution after carburizing are in good agreement with the experimental results, indicating high simulation accuracy. The volume fraction of martensite and hardness of the carburized layer after low pressure carburizing under strong infiltration+diffusion process are simulated, and the distribution of the two is consistent. Comparing the simulation and experimental results of hardness of the specimen after low pressure carburizing under strong infiltration + diffusion process, the measured value is slightly higher than the simulated value, because the simulation result is the calculated average of a larger area.

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Numerical simulation on induction hardening of Cr12MoV die steel based on electromagnetic thermal coupling

Liu Shouhe, Yi Jianye, Xie Hui

Heat Treatment of Metals 2024, 49 (8): 225-231. doi:10.13251/j.issn.0254-6051.2024.08.039

Abstract （37）

PDF （3237KB）（29）

Finite element numerical simulation method was adopted to study the effects of power frequency, current density and induction coil moving speed on surface temperature field of the workpiece during induction hardening for the Cr12MoV die steel. According to Maxwell's equations and non-stationary thermal conductivity differential equations, a moving dual-loop induction coil model coupled with electromagnetic field and temperature field was established, by which the temperature field on surface of the workpiece was calculated. And the simulation results were verified by induction hardening experiments. The results show that the temperature rising curve at the center of the workpiece surface is a bimodal curve. The rate and amplitude of temperature rising increase with the increase of power frequency and current density, while decrease with the increase of induction coil moving speed. Through the hardness analysis in the thickness direction of the workpiece after hardening, it is found that the depth of the high-temperature region obtained by simulation calculation is roughly consistent with the depth of the hardened layer. The temperature rising curve measured in experiments basically matches the numerical simulation results, with a maximum error of about 7%, which shows that the process parameters for practical application can be optimized by numerical simulation method, realizing the precise control of depth of hardened layer and hardness of the workpiece after hardening.

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Computational method for unsteady heat transfer on surface of 45 steel during laser quenching

Zhang Wen, Guo Yutong, Zhang Lingcong, Shen Rui, Shi Hui, Bao Hanwei, Li Gangyan

Heat Treatment of Metals 2024, 49 (8): 232-241. doi:10.13251/j.issn.0254-6051.2024.08.040

Abstract （38）

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Temperature distribution of unsteady heat transfer during laser quenching of 45 steel was obtained by solving an explicit two-dimensional finite difference equation, and the effect of laser power on the surface temperature after single pass laser quenching was analyzed. Utilizing JMatPro, comprehensive phase transformation curves, as well as temperature-dependent thermophysical properties and phase transformation critical temperatures during heating and cooling processes of the material, were derived. Incorporating both the laser heat source and latent heat of phase transformation, a unsteady heat transfer model for the surface laser quenching of 45 steel was established. This model was then employed to conduct heat transfer analysis under both fixed and moving heat source conditions during laser quenching. The results show that the error of the maximum temperature calculation under fixed heat source condition is within 7%. When the laser irradiation time is 0.5 s and the power is between 1300 W and 2600 W, the surface temperature of the specimen can be effectively controlled between 720 ℃ and liquidus 1495 ℃, ensuring the occurrence of solid phase transformation during laser quenching process. The model is applied to single pass moving heat source laser quenching at high power, which can better reflect the actual temperature change trend.

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Numerical simulation and microstructure analysis of post-weld heat treatment for TC4 titanium alloy

Xie Benchang, Liu Xinyu, Zhang Le, Chen Yanzi, Cen Yaodong, Chen Lin

Heat Treatment of Metals 2024, 49 (8): 242-247. doi:10.13251/j.issn.0254-6051.2024.08.041

Abstract （59）

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Ansys software was used to simulate the welding and post-weld heat treatment(PWHT) process of the TC4 titanium alloy, and the changes of microstructure and residual stress of the welded and heat treated alloy were analyzed. The results show that during the welding process, the temperature of each layer of the weld varies due to different heat inputs. The peak temperature of the first layer weld is the lowest (2183.6 ℃), and the fifth layer is the highest (2337.8 ℃). Due to the different characteristics of thermal cycles experienced by each layer, the size of martensite in each layer of the weld zone changes from 19.5 μm to 96.2 μm. The weld zone after welding is mainly composed of α_m phase, a small amount of β phase, some α_t phase and precipitated α_g phase. After the PWHT, the α_m phase in the joint transforms into a secondary (α+β) phase, and it is XRD observed that the (0002)_α diffraction peak undergoes peak splitting, a new peak (110)_β appears at 2θ=39.6°, the full width at half maximum decreases by 5.56%-43.75%, indicating that the crystallinity of TC4 titanium alloy is improved with the elimination of residual stress. The residual stress after welding is mainly concentrated near the weld seam, which is a fracture prone location. The residual stress along the direction perpendicular to welding is symmetrically distributed, which is basically the same as the distribution of temperature field. After the PWHT, all the residual stresses are reduced.

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Numerical simulation of vacuum isothermal quenching process of H11 steel large module for die-casting dies

Tu Yujie, Li Bingchen, Chen Hao, Wu Xiaochun

Heat Treatment of Metals 2024, 49 (7): 1-8. doi:10.13251/j.issn.0254-6051.2024.07.001

Abstract （102）

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Based on the metal-thermo-mechanical coupled theory, multi-field coupled numerical models of the H11 steel large module (500 mm×500 mm×500 mm) during vacuum isothermal quenching was established, and the numerical simulation of different vacuum isothermal quenching processes was carried out to study the evolution of the temperature field, structure field and stress field. The results show that compared with direct quenching, isothermal quenching can effectively reduce the temperature difference and the stress between the core and surface during the cooling process of the module to avoid the risk of distortion and cracking. Vacuum isothermal quenching can increase the volume fraction of bainite in the core of the module while avoiding pearlite formation and carbides precipitating along the grain boundary, and with the increase of the isothermal time, the more core bainite will be generated. The experimental verification of vacuum isothermal quenching at 500 ℃ for 1 h carried out by using industrial equipment indicates that the temperature curves at different positions of the module are in good agreement with the simulation results, and the type of bainite formed in the core of the module after vacuum isothermal quenching is lower bainite with good toughness.

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Numerical simulation of temperature uniformity of large thin-walled shell parts during high pressure gas quenching

Wang Jing, Zhang Xiaojuan, Tong Daming, Gu Jianfeng, Zhou Zhongping, Bai Lu, Zhu Lijian

Heat Treatment of Metals 2024, 49 (7): 9-15. doi:10.13251/j.issn.0254-6051.2024.07.002

Abstract （79）

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Fluid-solid coupling simulations were carried out for the large thin-walled shells during high pressure gas quenching. The numerical model was included the vacuum high-pressure gas quenching furnace and the large thin-walled shells which were aerospace components. The temperature uniformity of the shell during high pressure gas quenching in the vacuum furnace was evaluated, and the shell temperature distribution was simulated corresponding to the different gas outlet positions, different furnace charging and flow diversion conditions. The results show that compared with the original model, the quenching methods of one-outlet scheme, one-shell charging in the center of furnace and adding baffles can improve the temperature uniformity of the shell by 8%, 30% and 12.5% respectively, and the results provide an optimized quenching scheme for controlling the deformation of the shell.

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Numerical simulation of spiral bevel gear quenching based on thermo-fluid-solid coupling model

Liu Ganhua, Deng Shiyi, Huo Xiaodong

Heat Treatment of Metals 2024, 49 (7): 16-21. doi:10.13251/j.issn.0254-6051.2024.07.003

Abstract （68）

PDF （2435KB）（86）

Based on thermo-fluid-solid coupling simulation, quenching and cooling process of 45 steel spiral bevel gears was numerical simulated, and the influence of quenching medium flow rate on quenching results was studied. It is found that the maximum relative errors between the cooling curves of thermo-fluid-solid coupling simulation and traditional simulation and experimental measurement are 9.2% and 7.4%, respectively. Moreover, more accurate prediction of temperature distribution under quenching medium flow conditions is achieved, verifying the accuracy and convenience of this method. When the inlet flow rate is 2 m/s, the maximum hardness value is 52.0 HRC, and the residual stress is mainly favorable compressive stress.

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