A finite element simulation for carburizing heat treatment of automotive gear ring incorporating transformation plasticity

Kim, Dong-Wan; Cho, Hoon-Hwe; Lee, Won-Beom; Cho, Kyun Taek; Cho, Yi-Gil; Kim, Se Jong; Han, Heung Nam

doi:10.1016/j.matdes.2016.03.047

Cited by 35 publications

(8 citation statements)

References 42 publications

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“…Li et al [15] simulated various residual stresses during carburization and quenching. In the literature [16][17][18][19], the carburizing heat treatment of other gear types, including gear ring, was simulated similarly. However, these studies did not perform simulation analysis on carburized gears during their actual work process.…”

Section: State Of the Artmentioning

confidence: 99%

Meshing Simulation and Strength Calculation of a Carburized Gear Pair

Li¹,

Zhang²,

Wnag³

2017

Int. j. simul. model.

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The material in the carburized layer of a carburized gear is nonlinear. However, no systematic theory and method is available to analyse the strength of nonlinear materials; thus, calculating the exact strength of carburized gears is difficult. The traditional method of calculating the strength of carburized gears considered the material as uniform, which is susceptible to make errors. To address this problem, a hierarchical simulation method was proposed to calculate the strength of carburized gears. The strength calculation principle of carburized gears was first analysed. Then, a solid modelling method of carburized gears was presented based on the extraction technology of the layered homogeneous material. Finally, the meshing process of carburized gears was simulated, and the distribution and variation laws of the root, contact, and shear stresses during the meshing process were determined accurately. Results show that the shear stress of carburized gears initially increases and then decreases along with depth direction, and the maximum value appears in the surface below. However, the shear stress of non-carburized gears decreases linearly. The equivalent stress of the two kinds of gears decreases linearly with depth direction, whereas the decreasing amplitude of the carburized gears is larger than that of the non-carburized gears. A significant error in the calculation of the strength of carburized gears can be clearly observed using the traditional method. By selecting the appropriate parameters, the method proposed in this study can be used to simulate the meshing process of the carburized gear pair and calculate its strength accurately.

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Section: State Of the Artmentioning

confidence: 99%

Meshing Simulation and Strength Calculation of a Carburized Gear Pair

Li¹,

Zhang²,

Wnag³

2017

Int. j. simul. model.

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“…The increasing demand of gears drive in these fields leads to a much more rigorous requirement for the surface integrity [3,4], geometric and physical performances [5,6], and fatigue life [7] of it. As a vital process in gear manufacturing, heat treatment exerts an enormous function on the enhancement of gear quality such as strength, surface hardness, wear and fatigue behaviors [8,9]. However, excessive and uncontrolled distortion may inevitably occur due to the comprehensive impacts of the materials, structures, quenching medias, thermal stresses and phase transformations during the heat treatment [10,11].…”

Section: Introductionmentioning

confidence: 99%

Prediction and Minimization of the Heat Treatment Induced Distortion in 8620H Steel Gear: Simulation and Experimental Verification

Shao

Tang

et al. 2022

Chin. J. Mech. Eng.

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The considerable heat treatment induced runout value in the end face of the automobile main reducer gear is always dimensionally out of tolerance. It directly affects the dimensional accuracy, the grade of carburized and hardened gears, and the post-quenching manufacturing costs. In this study, three dimensional numerical models were developed to simulate the carburizing-quenching process of gear based on the multi-field coupling theory using DEFORM software. The results indicated that the ununiform cooling rate of the gear caused by the asymmetry of the web structure would result in the ununiform distribution of martensite, leading to the large runout value at the end face of the gear. Therefore, a novel method was proposed to minimize the heat treatment induced runout value. It was found that the heat treatment induced runout value could be effectively controlled by the addition of a compensation ring and the support of a rod structure. Further experiments showed that the average runout value of the gear end face before and after the proposed heat treatment method were about 0.023 mm and 0.059 mm respectively, which was in good agreement with the simulated results. The novel approach proposed in this study led to a reduction of the gear runout value by 70.0%‒76.9% compared to that of the original heat treatment process, which may serve as a practical and economical way to predict and minimize the heat treatment induced distortion in drive gear.

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“…The simulation analysis of carburizing-quenching treatment of gear have been paid much attention to reduce the deformation of gear, but the influences of macro-segregation in the core of round steel bar on deformation of gear have always been ignored, so the simulated hot-rolling process is novel but essential to control the morphology of macro-segregation region, while not only to research the distribution of the stress field and tem-perature field of workpiece during rolling process [6,7].…”

Section: Introductionmentioning

confidence: 99%

Finite element analysis on shape deformation of the macro‐structure region during hot‐rolling process for gear steel FAS3420H and its modification

Liu

Wang

2021

Materialwissenschaft Werkst

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The rectangular macro‐segregation region in the core of hot‐rolled steel bar has a great influence on the heat treatment distortion of an automotive gear steel FAS3420H. In order to understand the distortion process of the segregation region during hot‐rolling process, a finite element (FE) analysis of the whole hot‐rolling process was carried out by software DEFORM‐3D, and a constructed constitutive model was embedded into DEFORM‐3D to describe the deformation process. The results show there is an inhomogeneous strain distribution at the cross‐section of hot‐rolled round bar, which results in uneven distortion of the segregation region in different directions. A square segregation region, which can reduce inhomogeneous distortion of gear in the subsequent heat treatment, is obtained after being rolled by simulation calculation verified through experiment.

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A finite element simulation for carburizing heat treatment of automotive gear ring incorporating transformation plasticity

Cited by 35 publications

References 42 publications

Meshing Simulation and Strength Calculation of a Carburized Gear Pair

Meshing Simulation and Strength Calculation of a Carburized Gear Pair

Prediction and Minimization of the Heat Treatment Induced Distortion in 8620H Steel Gear: Simulation and Experimental Verification

Finite element analysis on shape deformation of the macro‐structure region during hot‐rolling process for gear steel FAS3420H and its modification

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