Effect of Spray Quenching Rate on Distortion and Residual Stresses during Induction

Hardening of a Full-Float truck Axle

Effect of Spray Quenching Rate on Distortion and Residual Stresses during Induction

Hardening of a Full-Float truck Axle

Zhichao (Charlie) Li, and B. Lynn Ferguson DANTE SOFTWARE, Cleveland, OH 44130, USA

 Valentin Nemkov, Robert Goldstein, and John JackowskiFluxtrol, Inc. 1399 Atlantic Blvd, Auburn Hills, MI 28326, USA

Greg FettDana Corporation, 3939 Technology Drive, Maumee, OH43537,

USA

 ASM HTS 2013, 27th Conference and Exposition15 September – 18 September 2013, Indianapolis, Indiana, USA

IntroductionIntroduction

Induction hardening involves multiple phenomena, including: electromagnetic, thermal, metallurgical, stress and deformation.

Flux software (electromagnetic and thermal capabilities) is coupled with DANTE (thermal, phase transformation, stress and distortion capabilities).

Case chosen for study is a full-float axle, dimensions typical for axles manufactured and hardened by Dana Corporation.

This study is a follow-up of the work presented at HES 2013, Padua, Italy.

Effect of spray quenching rate on residual stresses and distortion.

Slide 2

Mutually Coupled Phenomena in Induction Heating Process

Mutually Coupled Phenomena in Induction Heating Process

Slide 3

Axle Geometry and FEA ModelAxle Geometry and FEA Model

Slide 4

Material: AISI 1541. Shaft dimension:

• Length: 1008 mm.

• Diameter: 34.93mm.

• 35 spline teeth.

Single tooth model with cyclic symmetry BC.

FEA Meshing.• 47746 hexahedral

elements.

• 16038 tetrahedral elements.

Phase TransformationPhase Transformation

Slide 5Material: AISI 1541

Diffusive transformation

Martensitic transformation

Two-Turn Inductor Coil Design and Flux2d Modeling

Two-Turn Inductor Coil Design and Flux2d Modeling

Slide 6

Full assembly of a two-turn axle scan coil with quench body

Fillet area of axle modelled with Flux 2D, mesh elements

Process CycleProcess Cycle

Slide 7

Spray quench is 25.4 mm below the inductor.

Spray quenchant: 6% polymer solution.

Severity of spray quench (heat transfer coefficient):

• Aggressive: 25,000 (W/m2C).

• Medium:12,000 (W/m2C).

• Mild: 5,000 (W/m2C).

Power Distribution in Three Regions Modeled by Flux2D

Power Distribution in Three Regions Modeled by Flux2D

Slide 8

Fillet Shaft Spline

Power Mapping from Flux2D to DANTEPower Mapping from Flux2D to DANTE

Slide 9

Temperature Predicted by Flux2D

Temperature Predicted by DANTE

Good agreement on the temperature distributions predicted by Flux2D and DANTE.• The power mapping from Flux2D to DANTE is valid.

DANTE Results in Radius and FlangeAt the End of 9 Second Dwell

DANTE Results in Radius and FlangeAt the End of 9 Second Dwell

Slide 10

Temperature Austenite Hoop Stress Radial Disp. Axial Disp.

DANTE Results in Radius and FlangeAt 16.5 Second during IH Process

DANTE Results in Radius and FlangeAt 16.5 Second during IH Process

Slide 11

Temperature Austenite Hoop Stress Radial Disp. Axial Disp.

DANTE Results in Radius and FlangeAt 130.15 Second during IH Process

DANTE Results in Radius and FlangeAt 130.15 Second during IH Process

Slide 12

Temperature Austenite Hoop StressMartensite Axial Disp.

13

Animation: IH Process HTC=12,000 W/m2C Animation: IH Process HTC=12,000 W/m2C

14

Animation: IH Process HTC=5,000 W/m2C Animation: IH Process HTC=5,000 W/m2C

15

Animation: IH Process HTC=25,000 W/m2C Animation: IH Process HTC=25,000 W/m2C

Axial Residual StressesEffect of Spray Quenching Rate

Axial Residual StressesEffect of Spray Quenching Rate

Slide 16

Unit: MPa

Hoop Residual StressesEffect of Spray Quenching Rate

Hoop Residual StressesEffect of Spray Quenching Rate

Slide 17

Unit: MPa

Axial DisplacementsEffect of Spray Quenching RateAxial DisplacementsEffect of Spray Quenching Rate

Slide 18

Unit: mm

Evolution Plots at the Cross SectionEffect of Spray Quenching Rate

Evolution Plots at the Cross SectionEffect of Spray Quenching Rate

Slide 19

The cross section selected is 614.15 mm from the flange end.

Four points are selected to plot the process evolution. • Temperature, phase, stress, and displacement.

• Depth of the four points: 0.0mm, 3.99mm, 8.12mm, 17.47mm.

20

Temperature and Phase PlotsHeat Transfer Coefficient (12,000 W/m2C)

Temperature and Phase PlotsHeat Transfer Coefficient (12,000 W/m2C)

21

Axial Stress and Displacement PlotsHeat Transfer Coefficient (12,000 W/m2C)

Axial Stress and Displacement PlotsHeat Transfer Coefficient (12,000 W/m2C)

22

Temperature and Phase PlotsEffect of Cooling Rate

Temperature and Phase PlotsEffect of Cooling Rate

23

Axial Stress and Displacement PlotsEffect of Cooling Rate

Axial Stress and Displacement PlotsEffect of Cooling Rate

24

SummarySummary

Electromagnetic modeling by Flux and thermal/stress modeling by DANTE were successfully coupled.

The effect of spray quenching severity on residual stresses and distortion are predicted.

Higher spray rate increases the magnitudes of surface compression, core tension, as well as the length growth.

The modelling procedure developed in this study is promising for design optimization, in-process failure prevention, and service property prediction.

Next step: tempering process modeling; loading model with residual stresses; comparing with low cycle and high cycle fatigue life experiments.