《熱處理工藝設計有限元分析軟件.ppt》由會員分享，可在線閱讀，更多相關《熱處理工藝設計有限元分析軟件.ppt（60頁珍藏版）》請在裝配圖網(wǎng)上搜索。

熱處理工藝設計有限元分析軟件,,CopyrightDCTInc.2010,DANTE是以有限元為基礎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,,,模擬分析結果殘余應力碳分布微觀結構相分布硬度分布熱處理變形預測,,,DANTE功能介紹,殘余應力,碳分布,怎樣應用DANTE節(jié)約制造成本、提高設計質(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)量熱處理零件設計在零件初始設計階段考慮熱處理的影響對改新設計的熱處理過程預測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,殘余應力,DANTE模擬的典型零件,DANTE軟件的結構,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測的微觀相分布(traceacrossmid-height),AISI5120齒輪坯滲碳和油淬火后變形預測,ComparisonofPredicted&ResidualStressProfilesCalculatedfromX-RAYandNeutronDiffractionTestsfor5160QuenchedSteelBars,OilQuenched&Tempered,IntensivelyQuenched&Tempered,,,圓柱件淬火回火后殘余應力,,AISI1045Steel帶導向槽軸形件,模擬結果和實驗數(shù)據(jù)比較變形、硬度、和微觀結構,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:變形預測,飛機起落架熱處理變形模擬預測,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力場,齒輪經(jīng)不同淬火工藝后的殘余應力,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力分布,AISI4150OilQuench,AISI9310Carburization+OilQuench,齒輪設計過程中考慮材料選取和熱處理工藝?,利用殘余壓應力提高齒輪壽命或降低齒輪重量,齒輪動態(tài)疲勞測試應力重新分布:原設計,齒輪動態(tài)疲勞測試應力重新分布:優(yōu)化設計,斜錐齒輪淬火模擬:溫度和奧氏體,斜錐齒輪淬火模擬:最大最小主應力,油孔周圍的溫度場分布不均勻,汽車曲軸件感應淬火過程模擬:感應加熱3.0秒后的溫度場,奧氏體層大概2.5mm,汽車曲軸件感應淬火過程模擬:感應加熱3秒后奧氏體分布,汽車曲軸件感應淬火過程模擬:冷卻過程中兩個關鍵位置的內(nèi)應力變化,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,表面脫碳對殘余應力及淬火裂紋的影響,預測的表面拉應力很淺.脫碳層的深度決定表面拉應力層的深度.表面層的拉應力可能會造成淬火過程中或后加工中表面開裂.表面拉應力層的深度大約是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測的殘余應力,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,熱處理后殘余應力預測,,,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力學模型,Definesmechanicalpropertiesforeachphaseasafunctionof%C,T,ε,εEmbeddedmixturemodelcalculatesthemechanicalbehaviorofcompositefrommechanicalbehaviorofindividualphasesAccountsfortransformationinducedplasticityEffectivelycalculatesthematerialresponseduringloading,unloading,andreverseloading,*DANTEusestheIR100AwardwinningBCJMaterialModeldevelopedatSandiaNationalLaboratory,利用傳統(tǒng)應力-應變數(shù)據(jù)擬合力學模型參數(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,聯(lián)系方式:DeformationControlTechnology,Inc.7263EngleRoad,Suite105,Cleveland,Ohio,USAPhone:(440)234-8477Fax:(440)234-9140E-mail:support@DeformationCWebsite:www.DeformationC,