熱處理工藝設(shè)計有限元分析軟件.ppt

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熱處理工藝設(shè)計有限元分析軟件,,CopyrightDCTInc.2010,DANTE是以有限元為基礎(chǔ)的熱處理工藝模擬商業(yè)化軟件.可以精確模擬加熱和冷卻工藝中的傳熱過程.經(jīng)實驗驗證的力學(xué)模型、相變模型、滲碳模型和數(shù)據(jù)庫.可用于模擬液體浸入淬火、氣淬淬火、快速淬火、模具淬火.可用于模擬低溫回火熱處理工藝.,DANTE?熱處理工藝分析軟件,,,模擬分析結(jié)果殘余應(yīng)力碳分布微觀結(jié)構(gòu)相分布硬度分布熱處理變形預(yù)測,,,DANTE功能介紹,殘余應(yīng)力,碳分布,怎樣應(yīng)用DANTE節(jié)約制造成本、提高設(shè)計質(zhì)量？,通過軟件來“模擬實驗”了解熱處理工藝參數(shù)對變形，殘余應(yīng)力，微觀組織和硬度的影響確定造成熱處理變形、缺陷等問題的原因排除熱處理工藝問題、改進和優(yōu)化熱處理工藝優(yōu)點在保證熱處理質(zhì)量的前提下降低熱處理成本，比如滲碳時間節(jié)約熱處理零件后加工成本提高熱處理零件質(zhì)量熱處理零件設(shè)計在零件初始設(shè)計階段考慮熱處理的影響對改新設(shè)計的熱處理過程預(yù)測DANTE是經(jīng)實驗驗證熱處理模擬軟件,CAD&ModelBuilding,DANTE模擬分析方法,微觀組織,變形,殘余應(yīng)力,DANTE模擬的典型零件,DANTE軟件的結(jié)構(gòu),零件熱處理模擬分析例子和驗證,AISI5120齒輪坯油淬火工藝模擬,油淬火的程序:奧氏體化溫度:870C滲碳爐碳勢:0.85%淬火油溫度(5min.):132C空冷至室溫齒輪坯的尺寸:ID=35mmOD=57mmHeight=22mm軸對稱網(wǎng)格:380elements,2D,AxisymmetricModel,RingwithCenterHub,滲碳過程,Microprobevs.Simulation,,AISI5120齒輪坯滲碳和油淬火后模擬預(yù)測的微觀相分布(traceacrossmid-height),AISI5120齒輪坯滲碳和油淬火后變形預(yù)測,ComparisonofPredicted&ResidualStressProfilesCalculatedfromX-RAYandNeutronDiffractionTestsfor5160QuenchedSteelBars,OilQuenched&Tempered,IntensivelyQuenched&Tempered,,,圓柱件淬火回火后殘余應(yīng)力,,AISI1045Steel帶導(dǎo)向槽軸形件,模擬結(jié)果和實驗數(shù)據(jù)比較變形、硬度、和微觀結(jié)構(gòu),曲軸件熱處理模擬,DuringCooling,曲軸熱處理模擬:溫度,曲軸熱處理模擬:奧氏體,曲軸熱處理模擬:切開面奧氏體,曲軸熱處理模擬:變形預(yù)測,飛機起落架熱處理變形模擬預(yù)測,飛機起落架高度大約3.5米材料:300M,飛機起落架淬火過程中的溫度場,飛機起落架淬火后的預(yù)測變形,變速器輸出軸熱處理過程中的溫度場,變速器輸出軸熱處理過程中的應(yīng)力場,齒輪經(jīng)不同淬火工藝后的殘余應(yīng)力,10:1maximumtominimumloadratioServohydraulictestmachineat40cpsRunoutisdefinedas107cycleswithoutfailure,SchematicofTestFixturing,單齒疲勞強度試驗,單齒疲勞強度試驗數(shù)據(jù):BenefitofREM,IQ~800MPa~120ksi,OQ~1000MPa~148ksi,StressFree~1600MPa~232ksi,StressStateinTestGearat1400lbs.BendingLoad,MPa,單齒疲勞載荷下齒輪應(yīng)力分布,AISI4150OilQuench,AISI9310Carburization+OilQuench,齒輪設(shè)計過程中考慮材料選取和熱處理工藝?,利用殘余壓應(yīng)力提高齒輪壽命或降低齒輪重量,齒輪動態(tài)疲勞測試應(yīng)力重新分布:原設(shè)計,齒輪動態(tài)疲勞測試應(yīng)力重新分布:優(yōu)化設(shè)計,斜錐齒輪淬火模擬:溫度和奧氏體,斜錐齒輪淬火模擬:最大最小主應(yīng)力,油孔周圍的溫度場分布不均勻,汽車曲軸件感應(yīng)淬火過程模擬:感應(yīng)加熱3.0秒后的溫度場,奧氏體層大概2.5mm,汽車曲軸件感應(yīng)淬火過程模擬:感應(yīng)加熱3秒后奧氏體分布,汽車曲軸件感應(yīng)淬火過程模擬:冷卻過程中兩個關(guān)鍵位置的內(nèi)應(yīng)力變化,脫碳后的碳分布脫碳層大約0.1mm.,,,,,齒輪熱處理過程中表面脫碳模擬,表面脫碳對殘余應(yīng)力及淬火裂紋的影響,預(yù)測的表面拉應(yīng)力很淺.脫碳層的深度決定表面拉應(yīng)力層的深度.表面層的拉應(yīng)力可能會造成淬火過程中或后加工中表面開裂.表面拉應(yīng)力層的深度大約是0.3mm.,3D單齒模型,端面齒輪模壓淬火過程模擬,,AxialDisplacementAfterPressQuenchwithLoadStillAppliedcontourplotshowsthewebbowingdownward(redispositiveinthedownwarddirection)thetoptoothhasexpandedupwardby0.24mm(0.009”)andthebottomtoothhasexpandeddownwardby0.02mm(<0.001”),SpringbackasDieLoadisRemovedtoothsectionliftsapproximately2.3mm(0.090”)afterremovingthepressloadandfinalcoolingfromtheoiltemperatureof140Ftoroomtemperature.,3D單齒模型,端面齒輪模壓淬火過程模擬(cont.),WithoutShimming,WithShimming,端面齒輪模壓淬火過程模擬(cont.),端面齒輪模壓淬火后預(yù)測的殘余應(yīng)力,環(huán)形齒輪模壓淬火過程模擬,3D單齒模型,環(huán)形齒輪模壓淬火后的變形,,Scenario445secondsairtransfer100secondsdwell,Scenario6120secondsairtransfer20secondsdwell,Scenario545secondsairtransfer20secondsdwell,加載前下模對齒輪冷卻的影響,熱處理后殘余應(yīng)力預(yù)測,,,Unit:MPa,PressQuenchScenario4,熱處理后齒輪加工過程中的變形,DANTE模型和數(shù)據(jù)庫傳熱模型:加熱和冷卻熱邊界碳擴散模型相變模型力學(xué)模型,利用熱電偶數(shù)據(jù)反求熱邊界條件,DataAcquisitionTime-temperaturedatafromthermocouplesDataAnalysisUsingoptimizationorreversecalculationtodetermineheattransfercoefficients,利用熱電偶數(shù)據(jù)反求熱邊界條件(Cont.),碳擴散模型,EstablishescarbonprofilewithinthecomponentduringcarburizationMassdiffusionmodelisappliedModelingfurnacegascarburizingprocessesSurfacecarbonpotentialfollowingtimedependentcurvebasedonarisetoequilibriumcarbonlevelModelingvacuumcarburizingprocessesSurfacecarbonfluxintermsofthecarburizingschedule,Customkineticsmodel:KineticsbasedondilatometrydataKineticsbasedonTTTcurvesKineticsbasedonCCTcurvesKineticsbasedonJominydataGlobalkineticsmodel:Theuserinputsthechemistrytocalculatephasevolumesbasedoncoolingpath,ortocalculateJominyhardnessDANTEkineticspredict:Volumefractionsofferrite,pearlite,bainite,andmartensitethroughoutanarbitrarycoolingpathKineticsverification:RunDANTEdilatometrymodel,andcomparewiththeexperimentsRunDANTEutilitiestoobtainTTT(CCT)curves,andcomparewithreferencesRunDANTEJominyend-quenchmodel,andcomparewithexperiments,相變模型及參數(shù)確定,典型熱及相變膨脹試驗,利用熱及相變膨脹來測量確定相變模型參數(shù),JominyChecking,FittingTolerance,DilatometryFitting,TTTFitting,相變模型參數(shù)的擬合方法,DANTE力學(xué)模型,Definesmechanicalpropertiesforeachphaseasafunctionof%C,T,ε,εEmbeddedmixturemodelcalculatesthemechanicalbehaviorofcompositefrommechanicalbehaviorofindividualphasesAccountsfortransformationinducedplasticityEffectivelycalculatesthematerialresponseduringloading,unloading,andreverseloading,*DANTEusestheIR100AwardwinningBCJMaterialModeldevelopedatSandiaNationalLaboratory,利用傳統(tǒng)應(yīng)力-應(yīng)變數(shù)據(jù)擬合力學(xué)模型參數(shù),PhaseTransformationKineticsFittingforHeating&CoolingUsesdilatometrydataUsesTTT&CCTorCHTdataUsesJominydata(cooling)TTT,CCT,andJominyDiagramGeneratorMechanicalParametersFittingUsestemperaturedependentcompressionandtensiontestdataHeatTransferCoefficientDeterminationUsesthermocoupledataDANTE/GCARBforGasCarburizationProcessDesign(Time,Temperature,andCarbonPotential)DANTE/VCARBforVacuumCarburizationBoost/DiffuseScheduleDesign.,DANTE附屬工具,DANTE軟件購買選擇-AnnualLicensing(Seat)-PerpetualSoftwareLicensingwithMaintenanceAgreement-Training&TrialLicense-Tools&UtilitiesMechanicalDataFittingKineticsFittingJominyHardnessPredictor,DeformationControlTechnology,Inc.providesconsultingservicesonbothheattreatmentmodelingandmetallurgicalworks.DeformationControlTechnology,Inc.alsoprovidesDANTElicenses.AnnualLicensing(Seat).PerpetualSoftwareLicensingwithMaintenanceAgreementTraining&TrialLicense.UtilitiestosupporttheDANTEsoftware,includingbothmechanicalandphasetransformationkineticsfitting.,DCT熱處理模擬和咨詢服務(wù),聯(lián)系方式:DeformationControlTechnology,Inc.7263EngleRoad,Suite105,Cleveland,Ohio,USAPhone:(440)234-8477Fax:(440)234-9140E-mail:support@DeformationCWebsite:www.DeformationC,