The quenching of a metal component with a channel section in a water tank is numerically simulated. Computational fluid dynamics (CFD) is used to model the multiphase flow and the heat transfer in film boiling, nucleate boiling and convective cooling processes to calculate the difference in heat transfer rate around the component and then combining with the thermal simulation and structure analysis of the component to study the effect of heat transfer rate on the distortion of the U-channel component. A model is also established to calculate the residual stress produced by quenching. The coupling fluid-thermal-structural simulation provides an insight into the deformation of the component and can be used to perform parameter analysis to reduce the distortion of the component.Quenching is a common manufacturing process to obtain unique service performance properties of metallic parts by controlling the amount and the morphology of micro-structural constituents. As it is a complex multi physics problem, it is essential to couple fluid, thermal, phase transformation, microstructural and mechanical behaviour to describe the unusual complex phenomenon. The phase transformation during quenching and the final phase constituents result in different microstructures, which depend on cooling rate and chemical composition of the steel. The cooling rate at part surface highly depends on the flow and the thermo-physical properties of quenchant and the thermo-chemical reactions occurring at the interface. Non-uniform heat transfer and phase transformation associated with large temperature gradients can lead to the difference in variation of volume (expansion or contraction) within component and, as a result, produce high residual stresses in quenched steels. The internal stresses can produce distortion and even cracking. Each of the phenomena included in the quenching process and the coupling of some individual physical problems has been addressed by numerical methods [1][2] . There are a number of simulation works focusing on phase transformation, microstructure, residual stress and mechanical behaviour [2][3][4][5][6][7] . Due to the studies on the theory and the numerical simulation of the individual events that occur during quenching and the computational method for fast and accurate prediction of the multi-physical phenomenon in the last three decades, the simulation of quenching process became realistic and several commercial software packages had been developed to be capable of simulating quenching process, such as DANTE, DEFORM-HT, FORGE, HEARTS, SYSWELD and Quench Simulator. However, most studies consider the quenching process as a thermalmicrostructural-mechanical problem [1][2] and these software are incapable of coupling with dynamic characteristics of fluid in quenching tank, which determines the local cooling rate at part surfaces.Coupling quenching simulations with computational fluid dynamics (CFD) is a major interest [8][9] . However, fluid-thermal simulation in most of the research is focused on single phase l...