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Outline
Introduction to Heat treatment process Industrial need of a simulation software System design of CHT- q/t Database design Enmeshment of Box shape workpiece Mechanical properties prediction after quenching Case study with CHT- q/t Industrial application of CHT- bf and CHT- cf Summary
Part information
Property prediction
Database
Furnace information
Workpiece Material
Initial condition
Workpiece
Furnace
Load pattern
Thermal schedule
Module 1 Workpiece classification & enmeshment Workpiece shape classification Enmeshment by Biot no.
Module 2 Heating
Module 3 Cooling Heat transfer for gas quenching in same furnace used in heating DB4 Quenchant DB
Heat transfer for oil quenching in tank (load with fixture, single workpiece without fixture)
Module 4 Phase transformation prediction (Austenite to pearlite / bainite / martensite) Comparing cooling curve with TTT diagram to determine microstructure Mapping of microstructure to properties
Database design
CHT-q/t needs extensive database to increase its applicability, as most of the modules strongly depend on database. The TTT and quenchant database are the new addition. Material and properties
It comprises of workpiece as well as furnace materials. Considers non-linearity of properties Addition of TTT diagrams for steels
Workpiece shape
13 basic shapes
Furnace
Batch & Continuous furnace for heating Dual chamber furnace, vacuum furnace, quenchant tank for cooling
1600
1400
1200
1000
800
600
400
200
Steps for the conversion of the TTT diagrams in tabular format Convert in digital format Pick the start and finish curves at temperature duration of 20 deg The value range from Austenitic start to martensitic start Store Ms and Mf values as well
TTT Database as shown in CHT- q/t User has the option to add or edit the TTT database as well
Relationship between gas pressure and the heat transfer coefficient at 500 degree C and 15m/s
Reference:
Torsten holm, Soren segerberg, Gas quenching branches out, advanced materials and processes, 1996.
TA-B B-C
Boiling Boiling stage sage
TB-C A-B
Convection stage
1000 0 0 200 400
600
800
Temperature,
The quenchant database considers the variation of convective heat transfer coefficient in all the three stages i.e. film boiling, bubble boiling and convection stages during liquid quenching
Classification of workpiece
Class Class I Box 2-stacked brick Shapes Class II Cylinder Hollow cylinder Base 2-step shaft 3-step shaft Class III Cone Hollow cone cone Class IV Sphere Class V Torus
Class I
The enmeshment was one dimensional for CHT- bf and CHT- cf The desired output of the hardness value at all the internal locations of part led to the development of 3-dimensional enmeshment.
3-Dimensional enmeshment
Classification of workpiece by Biot number Case 1: Bi .1 Lumped heat capacity model Case 2: Bi > .1 Exact model
Lumped heat capacity model
Input Conditions: The dimensions of the box (D1, D2, & D3). The initial temperatures of the part. Temperature of the quenchant gas.
T Ta = exp[ Bi F0 ] Ti Ta
Where, Ta is the ambient temperature Ti is the initial temperature of part F0 (Fourier number) is F = .t and
0
Lc
k C p
Thus we can get the final temperature T, by using the above equations Conductivity and specific heat as a function of temperature
x =
D1 n
y =
D2 l
z =
D3 m
Boundary nodes
i 0, n 0, n 0,n 0, n j (1 to L-1) (0 to L) (0 to L) (0 to L-1) k 0 1 m-1 m i 0, n 0, n 0,n 0, n j (1 to L-1) (0 to L) (0 to L) (0 to L-1) k 0 1 m-1 m
Corner nodes: (0, 0, 0) (n, 0, 0) (0, L, 0) (n, L, 0) (0, 0, m) (n, 0, m) (0, L, m) (n, L, m)
Properties to be determined Hardness Ultimate Tensile Strength Yield Strength Approach: Analytical approach for as quenched. Hardness value for all the nodes to get hardness distribution. For other properties equations used, as a function of hardness. The average value of hardness used to determine other properties. Database approach for as tempered.
Workpiece
Furnace
Load pattern
Thermal schedule
Module 1 Workpiece classification & enmeshment Workpiece shape classification Enmeshment by Biot no.
Module 2 Heating
Module 3 Cooling Heat transfer for gas quenching in same furnace used in heating DB4 Quenchant DB
Heat transfer for oil quenching in tank (load with fixture, single workpiece without fixture)
Module 4 Phase transformation prediction (Austenite to pearlite / bainite / martensite) Comparing cooling curve with TTT diagram to determine microstructure Mapping of microstructure to properties
Hardness
Microstructure after quenching
The kinetics of the growth of ferrite and pearlite are described using the Avrami-Johnson-Mehl equation where, w : volume fraction of austenite transformed b,n : coefficient and exponent of the austenite transformation kinetics, t : time ln (1 ws ) ts : start time log[ln (1 w ) / ln (1 w )]
tf : finish time
ws
w = 1 exp b.(t t s )
n=
= 0.01 w f = 0.99
log t s (T ) / t f (T )
b=
t s (T )
Hardness Calculation
A continuous cooling curve is divided into constant temperature steps with appropriate times . It is assumed that the horizontal parts of this step function cause a transformation comparable to the transformation occurring at the individual temperatures in the isothermal TTT-diagram. By an iteration of the transformation steps the final microstructure is derived.
step function
Temperature T
HV A
P HV HV B
M
Time t
Time log t
Regression Analysis
Hardness=f(C%, Martensite%) The equations of the form: H= ax2 +bx+c, x--- C% The equation at 50% Martensite y = -19.0476 x^2 + 64x + 20.1448 The equation at 80% Martensite y = 7.14286 x^2 + 50.6429x + 25.6529 Similarly, generating the HRC value for all the martensitic percentage points
Reference:
http://people.hofstra.edu/faculty/Stefan_Waner/RealWorld/newgraph/regressi onframes.html
Validation for low alloy steel (5140) having hardness of 167 HB. UTS calculated by the mentioned equation comes to be 572.278 Mpa And the UTS of a specimen having hardness 167 HB should be 573 Mpa Reference: Mechanical properties of Work Materials, Edmund Isakov Validation source: http://www.efunda.com/materials/alloys/alloy_home/steels.cfm
Conversion of HV to HB
Vickers Hardness Number (HV) from 85 150 200 250 300 400 500 to 149 199 249 299 399 499 670 HB = 0.959 HV - 0.8 HB = 0.949 HV + 0.9 HB = 0.954 HV - 0.7 HB = 0.922 HV + 7.3 HB = 0.944 HV +1.2 HB = 0.909 HV + 15.1 HB = 0.940 HV - 0.2 Equations to convert Vickers hardness (HV) into Brinell Hardness (HB)
Reference: http://www.efunda.com/materials/alloys/alloy_home/steels.cfm
Process
Time (mins)
Heating
2000
1500
1000
500
CALC_F
Workpiece Stainless steel Quench Gas Atmosphere Nitrogen Quench Pressure 2 bar Blower HP 200
Process Atmosphere Content Vacuum Vacuum Nitrogen (2 bar) Temperature (F) 70-1900 1900 200 Time (mins)
2000 Temperature (F) Meas. slow Meas. fast Calc. furnace Set Point Calc. fast Calc. fast
1500
1000
500
Future work
More case studies required to validate the system Enhance database for TTT diagram and quenchant Analytical approach to find convective heat transfer coefficient Analytical approach to find properties after tempering
Furnace name
Pit furnace, 416 Vertical Electric 5x8 45 x 60 2500 F 1000 120 kw or 409416.58 BTU/hr Air No preheat No [ ] Yes [ x] Yes Material Horse power Diameter Height Speed Weight Rate of cooling water [ x ] No [ ] No 303 2 14 4.5 1140 R.P.M 35 0 Graphite, 50lbs Alloy, 100lbs Alloy, 1000lbs
Pit Furnace
Body Shape (E.g. vertical, Horizontal) Heating type (E.g. direct/indirect fired, electric) External size(LengthWidth Height) or (diameter Height) Work space (LengthWidth Height) or (diameter Height) Maximum Operating Temperature Minimum Operating Temperature Connected heat input Atmosphere content Air preheated temperature Excess of preheated air (%) Vacuum Furnace Recirculation Fan (one fan at top)
R. H. Handles 1137 2
Load Pattern
Fixture type (basket/plate) Fixture shape (rectangular/round) Side wall, bottom (solid/net like) Fixture weight Fixture size (diameter , height) inch Load pattern, Fixture configuration Total quantity of workpiece in fixture Total weight of workpiece in fixture, lbs
Temp (F)
Conclusion: Part Temperature remains almost constant after 180 mins. The optimum cycle time prior to heat treating can be determined.
Temp (F)
Case study 2
Hitchiner part no. 87296 & 87292 17-4 stainless steel Two types of part(same material) present in the load 1. Qty = 300 2. Qty = 903 Wt. = 41 Wt. = 45 Thus average workpiece wt = 0.0715
Load pattern
Fixture type (basket/plate) Fixture shape (rectangular/round) Side wall, bottom (solid/net like) Fixture weight Fixture size (diameter , height) inch Load pattern, Fixture configuration Total quantity of workpiece in fixture Total weight of workpiece in fixture, lbs
Basket Round Solid 300 lbs 35, 25 Random (300 + 903)/2 = 601 (41 + 45)/2 = 43
Comparison of Result
Actual result
2500 2000 Temp (F) 1500 1000 500 0 0 50 100 150 200 250 Time (min) Temp (furnace) Temp (slow) Temp (fast)
Furnace name
Body Shape (E.g. vertical, Horizontal) Heating type (E.g. direct/indirect fired, electric) External size(LengthWidth Height) or (diameter Height) Work space (WidthLength Height) or (diameter Height) Maximum Heating Minimum Operating Temperature Fuel (combustion air) Connected heat input Atmosphere content Air preheated temperature (F) Excess of preheated air (%) Vacuum Furnace Opening area (inch2) Recirculation Fan
1800 1400 Natural gas 1000000, 60000 Btu/hr Endothermic (RX) with enriching gas, dilution air and ammonia additions 850 15 [ ] Yes 900 [x ] Yes Material Horse power Diameter Height Speed Weight Rate of cooling water [ ] No 330 5 10 inches 14.5 inches 1800 R.P.M 200 2 G.P.M (one fan at top) [ x ] No
Case study on all case furnace (with connected heat input 600,000 Btu/hr)
Load Pattern
Fixture type (basket/plate) Fixture shape (rectangular/round) Side wall, bottom (solid/net like) Fixture weight Fixture size (Length, width, height) inch Load pattern, Fixture configuration Rows Columns Layers of fixtures in furnace Total quantity of workpiece in fixture Total weight of workpiece in fixture, lbs Basket Rectangular Net like 45 lbs 29, 23, 4 Random 1x2x5 607 140.4 lbs
Result
Load takes around 65 minutes to reach the set point temperature, although the time allotted to reach the set point temperature is 30 minutes. In all case furnace, 10 fixtures are used for the part load and generally the parts are randomly placed in the fixture, leaving no room to change the part load design.
Result by CHT-bf (same load in furnace with higher heat input i.e increasing the connected heat input to 1 million Btu/hr) The time required by the load to reach
set point temperature reduced from 65 to 40 minutes, as we increased the connected heat input from 600,000 Btu/hr to 1000000 Btu/hr, thus saving around 25 minutes. Conclusion: The cycle time can be reduced. Conclusion about All case furnace: Connected heat input is the most important parameter for the All-case furnaces. We can determine suitable all case furnace for a specific load by CHT-bf
Limitation
Scheduling more than one type of parts of different geometry and material, we have to take average dimension and a closely resembling material. This may affect the result. Needs improvement for random load pattern Part load may require some assumptions Only applicable for heating process Needs a furnace efficiency parameter
Objective
To study the effects of change in the load quantity and giving recommendations for the thermal schedule redesign. To study the effect of change in load arrangement, determination of optimal load pattern from the calculated temperature values. To study the effect of part orientation on the quality and distortion and hence to determine best suited load orientation. To study the effect of belt speed and gross productivity on the thermal profile of parts and hence determine optimum belt speed and load capacity to maximize productivity.
Body Shape Heating type External size(Width Height) Or (diameter ) (in) Work space (Width Height) Or (diameter ) (in) Moving belt/conveyor width (in) Moving belt/conveyor unit weight Belt or conveyor return Opening area of the entrance zone (in2) Opening area of the end zone (in2) Fuel Air preheated temperature (F) Excess of preheated air (%) Vacuum Furnace
[ ]pipe
[x]box
[ ]Direct [x]indirect fired [ ]electric 90 x 96 56 x 56 54 (lbs/in2) 0.27 [x] internal 324 0 Natural gas 900 15 [ ] Yes [x ] No [ ] external
1 2 3 4
136 72 72 50
Case study 1
Gross productivity Name Material Weight XHD005 screw 1020 carbon steel 0.04 lbs Actual load width Height of layers Workpiece length Workpiece width Workpiece height
600 lbs/hr 54 inch 0.25 inch 0.25 inch 0.25 inch 0.156 inch
Temp (F)
Experimental result closely matches with the result given by CHT-cf The thermal profile of the part remains almost same irrespective of its location.
Work piece Name Work piece Material Work piece weight (lbs)
Gross productivity (lbs/hr) Actual load width (in) Height of layers (in) Workpiece length Workpiece width Workpiece height
Random load
Arranged load
Manual load arrangement Arranged load clubbing 15 parts as 1. Weight, part load pattern changed accordingly
Improvement in result
Uniformity of thermal profile in load Better quality achieved (confirmed by the quality department)
Limitation of CHT-cf
In the Atmosphere content, only atmosphere name can be mentioned. No option to quantify the atmosphere content. While simulating the part load by CHT-cf, distortion of parts are not considered, while in actual industrial practice the cycle time, production rate and load pattern arrangement are mostly considered keeping in view the final quality and distortion. Need to make the program stable and user friendly. Sometimes it gives some extra profiles in the temperature-time chart.
Summary
Several case studies validated with experimental results (using thermocouple) Accuracy of the temperature profiles predicted by CHT-bf and CHT-cf Judgment and approximation required in defining part load Described the methods to troubleshoot CHT-bf and CHT-cf Discussed in detail all the features i.e, database management Case studies and the experience helped in development of CHT- q/t as well