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DEFORM Simulation Results
2D Hot Forging and Air Cool of Gear Tooth Geometry
Holly Quinn12/04/2010
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DEFORM Model
• 2D Axisymmetric Model
• Workpiece (Yellow) is Plastic and 2200°F
• Top and Bottom Dies are Rigid. All pieces are 300°F.
• Workpiece will be re-meshed when interference exceeds 0.00099.
• Initial Contact Pairs:
1. WP to Bottom Die2. WP to Top Die
Top Die
Bottom Die
Workpiece
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Forging Simulation Setup and Results
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Forging Simulation Settings
• Main– Axisymmetric Geometry– Modes
• Deformation• Heat Transfer
• Step Settings– Starting Step = -1– Number of Steps = 100– 1 Step = 0.01” Die Displacement– Max Strain in WP/step = 0.1– Primary Die = Top Die
• Iteration Settings– Solver = Skyline– Iteration Method = Newton-Raphson– Convergence Errors
• 0.001 for Velocity• 0.01 for Force
• Process Conditions– Heat Transfer
• Environment Temperature = 68F• Convection Coefficient=5.787e-6
But/sec/in2F
– Diffusion• Environment Atom Content = 1.69% atm• Reaction rate coefficient = 1e-5 in/sec
• Advanced– Contact Error Difference Tolerations =
0.0009
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Materials
Top Die
Workpiece
Bottom Die
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Temperature, Final Time step
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Displacement
Flash
Flash
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Effective Stress
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Effective Strain
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Effective Strain Rate
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FlowNet Tracking of Material Flow
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Microstructure Post Processing of Forging
• Two Areas examined:– Points within gear “core”
• Points 6, 18, 21
– Points near exterior of gear tooth• Points 14, 15, 16
• Grain Orientation Plot• Average Grain Size from beginning to end
of forging (Step 1 – 43)
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Microstructure Post Processing Settings• Discrete Lattice: Cellular Automata, (50x50) Square• Horizontal and Vertical BCs: Periodic, Wrap Around• Grain boundary and Neighborhood:
– Grain Boundaries coupled to material flow: No– Neighbor Hood: Moore’s Neighborhood, R=1
• Dislocation Density Calculation Constants– ε0=1 Q=416,780 h0=0.00075– r0=2000 K=6000 m=0.0055
• Recrystallization Phenomena: DRX• Nucleation Conditions for new grains: Function of a threshold dislocation
density• Nucleation Conditions for new grains: n/a• Grain growth phenomena selection and material constants:
– Grain Growth: Function of GB migration velocity, constant=1• Flow Stress phenomena selection and material constants:
– n/a– ρi = 1– D=0.1– δ=0.1
• Initial MS Input:– Generate GB and orientations separately: System generate, average GS = 0– Generate GB Orientations: System generate, random– Initial dislocation density ρi=0.01
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Microstructure – Core Locations Grain Orientation, Step 1
P6
P18
P21
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Microstructure – Core Locations Grain Orientation, Step 43
P6
P18
P21
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Microstructure – Core Locations Grain Size Histogram, Step 1
P18
P21
P6
Point 6:Average GS=9.70
Point 18:Average GS=9.50
Point 21:Average GS=9.76
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Microstructure – Core Locations Grain Size Histogram, Step 43
Point 6:Average GS=2.05
Point 18:Average GS=1.89
Point 21:Average GS=2.02
P6
P18
P21
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Microstructure – Core Locations Grain Boundary Misorientation, Step 1
P18
P21
P6
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Microstructure – Core Locations Grain Boundary Misorientation, Step 43
P6
P18
P21
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Microstructure – Tooth Locations Grain Orientation, Step 1
P16
P15
P14
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Microstructure – Tooth Locations Grain Orientation, Step 43
P16
P14
P15
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Microstructure – Tooth Locations Grain Size Histogram, Step 1
Point 14:Average GS=9.80
Point 15:Average GS=9.59
Point 16:Average GS=9.81
P16
P15
P14
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Microstructure – Tooth Locations Grain Size Histogram, Step 43
Point 14:Average GS=1.97
Point 15:Average GS=2.07
Point 16:Average GS=1.91
P16
P15
P14
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Decreased Grain Size in Core and Tooth Areas (from Step 1 to 43)
• Gear Core Grain Size Changes– Point 6: 9.70 2.05– Point 18: 9.50 1.89– Point 21: 9.76 2.02
• Gear Tooth Grain Size Changes– Point 14: 9.80 1.97– Point 15: 9.59 2.07– Point 16: 9.81 1.91
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Cooling Simulation Setup and Results
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Air Cool Simulation Settings Pyrowear 53
• Main– Axisymmetric Geometry– Modes
• Deformation• Phase Transformation
• Mesh– #Structured Surface Mesh
Layers=2– Layer Thicknesses: 1=.005,
2=.01• Workpiece Initialization
– Don’t Initialize Temperature– Phase Volume Fraction
(Austenite)=1– Temperature = 2200°F
• Step Settings– Starting Step = -44
(last step of forging)– (Max) Number of Steps = 1000– 1 Step = 5°F– Min Temp Time Step = 5 sec– Max Temp Time Step = 30 sec– Duration = 5400 sec
• Process Conditions– Heat Transfer
• Environment Temperature = 68F• Coefficient=5.787e-06But/sec/in2F
• Boundary Conditions– Outside of Gear, all surfaces– Media Type = Air– Environment Temperature = 68°F– Convection Coefficient = 5.787e-06
But/sec/in2F– Symmetrical planes in vertical and
horizontal directions• Material
– Pyrowear, Heat Treat
*Heat Treat Wizard used for Model Setup
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Pyrowear 53 Temperature (°F)
Time Step #5Time = 25 seconds
Step #250Time = ½ hour
Step #425Time = 1 ½ hrs
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Pyrowear 53 Temperature (°F)
Step #155Time = 13 minutes
~1260°F
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Pyrowear 53 Phase Transformation, Time=0
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Pyrowear 53 Phase Transformation
Time=1000 seconds
Austenite Martensite Tempered Ferrite + Cementite
Temperature
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Pyrowear 53 Phase Transformation
Time=1800 seconds
Austenite Martensite Tempered Ferrite + Cementite
Temperature
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Pyrowear 53 Phase TransformationTime=5400 seconds
Ferrite Martensite Tempered Ferrite + Cementite
Tempered Martensite
Temperature
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Pyrowear HardnessStep 425, Time = 5400 seconds
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Pyrowear 53 TTT Diagram
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Pyrowear 53 Air Cool: Time Vs Temperature
Gear Cooling Rate (Pyrowear 53)
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
0 100 200 300 400 500 600 700 800 900
Time (seconds)
Tem
per
atu
re (
F)
Gear Core
Gear Case