03 The Heat Treatment Simulation Solution 171006

The Heat Treatment Simulation
Solution from ESI GROUP

An Overview
Copyright © ESI Group, 2006. All rights reserved.

Disclaimer and Copyright
Whilst this document has been carefully written and subject to

intensive review, it is the reader’s responsibility to take all necessary
steps to ensure that the assumptions and results from any finite
element analysis which is made as a result of reading this document
are correct. Neither ESI GROUP nor the authors can accept any
liability for incorrect analysis
The content of this document is an intellectual property of ESI

GROUP. No portion of this presentation may be reproduced, stored
in retrieval systems, or transmitted in any form or by any means,
including mechanical, photocopying, recording or otherwise, without
the prior written permission of ESI Group. All rights reserved

Technical Key Features
Heat Treatment

Coupled analysis
Electromagnetism
• Dissipated Joule
Energy • Temperatures
Thermal
Analysis
• Latent Heat
• Temperatures • Phase Proportions
Metallurgy
• Deformation-
• Temperatures • Chemical Composition energy • Temperatures
• Precipitations • Stresses • Phase Proportions
Diffusion - Precipitations Mechanical Analysis
• Chemical Composition
• Precipitations

Coupled analysis
• Carbon content Metallurgy
• Latent heat
Carbon diffusion • Temperatures
• Phase proportions
• Carbon content Heat transfer

Conduction, convection, radiation
CARBURIZING HEAT TREATMENT

Volume changes and
transformation plasticity
strain
Removal of
l the material
te rna austenitisation
0.015 s
x
+E rbide
a
history
c
se
ha
-P
γ
martensitic Carbides dissolution

0.01 transformation Ferrite + Carbon
+Initial,
undistorted grid
The more carbon

se dissolved at higher
Pha
0.005 α-
α temperature, the more grid
se
ha distortion at room
γ -P
temperature
0 +Interstitial dissolved
carbon
+ carbon, tetragonal distorted
grid
200 400 600 800 1000 1200 temperature

-0.005

What Counts to get Good Results
Heat Treatment

Important for the result quality
The major influence of the result quality do have
The mesh – a dedicated layered mesh is mandatory
Powerful element formulations

With linear and parabolic shape function
Mixture of tetra-, wedge- and hex elements possible
The quenching media
The thermal conductivity
The phase transformations

The Bainite transformation in case of parts with a higher BIOT number
The thermal strains
The yield stress of Austenite

Most yielding occurs in Austenite
The yield stress of Bainite

In case yielding occurs in Bainite

Biot – Number for a plane,
symmetrically cooled wall
h⋅L h: Heat transfer coefficient
Bi = L: Half of the thickness of the wall
k k: Thermal conductivity
Source:
‘Introduction to
Heat Transfer’,
Incropera,
DeWitt

Meshing for the Purpose of Heat
Treatment Simulation
Principles

Visual Mesh for Heat Treatment
Included in
all Heat
Treatment
packages
starting
from 2006
Courtesy: VCST

Meshing aspects
Meshing
Quenching requires a particular layered mesh

Due to high gradients in boundary layers
To avoid temperature oscillations in case of diffusion and a thermal shock
To generate layered meshes in 2D and 3D, Visual Mesh includes particular

capabilities
This reduces drastically the required time in comparison with other mesh generators
Without particular layered mesh

The computation time will be enormous – due to the number of generated elements in boundary
layers
The result quality will suffer
Set up and start of a quenching simulation
This takes in SYSWELD only a few minutes

Temperature profile – Highest
gradients in boundary layers
Heat flux in direction of the highest gradient
∂T
q = − k ( gradT ) ⋅ n = − k
∂n
°C
∅: 800 mm

Phase proportions – Highest
gradients in boundary layers
Courtesy: VCST

Stresses – Highest gradients in
boundary layers
In a very thin surface layer, the martensite transformation
happens, including a stress reversal and extremely high stress
gradients through thickness

Dedicated 2D layered meshing
50mm

Dedicated 3D layered meshing – Solid
growth – Tetrahedral filling
Courtesy: VCST

Important to understand
Without dedicated meshing tool, any heat treatment simulation tool

is
Incomplete
Not efficient
Excessively consuming computation time and hard disk space
The Heat Treatment Simulation Solution from ESI includes

Visual Mesh for Heat Treatment
Allows to generate dedicated heat treatment meshes with a minimum number of
elements and nodes, still providing best result quality
SYSWELD for Heat Treatment
All kinds of heat treatment analysis
Elements with linear and parabolic shape functions
Mixture of tetra-, wedge- and hex-elements in one model possible

Calibration of the CCT diagram of the
Steel
Example 16MnCr5

All CCT diagrams could be by default ‘improved’

They do not fit to the steel in use
Other manufacturer, etc.
They are too old
The generation of a CCT diagram is difficult and gives large
scatter
Etc.
The safe way to proceed is

To start with a CCT diagram that fits more general to the steel in
use
To calibrate the CCT diagram with a Jominy test of the steel in
use
Especially important for the Bainite transformation

Measured results of the Jominy-
Test
HV
Source
[28]
Distance from surface in mm

10 20 30 40 50 60 70

Calibration of the Bainite formation -
Jominy test - hardness computation

Jominy test: Hardness computation
in SYSWELD
Measured
Computed
• The shape is well reflected

Calibration of the Martensite
Transformation of Carburized Steel
Example 16MnCr5

Ms- / Mf-temperature = f(C%)
Start of Martensite
Transformation (MS)
Transformation Temperature
End of Martensite
Transformation (MF)
Mass %
C-Content

Martensite transformation as a
function of the carbon content
Red: 0.16%C
Yellow: 0.40%C
80% Level
Turquoise: 0.60%C
Blue: 0.80%C

Material Data Management
Welding and Heat Treatment

Material Data Management
• Done in Excel
• Easy to use

Usage in SYSWELD
•The in Excel defined

and generated data
can be directly
exported in a
SYSWELD format
•In SYSWELD, it can
be directly used for
display and simulation

Calibration of the Quenching Media
IVF Quenchotest

IVF portable Quenchotest
equipment to measure the
quenching fluid properties
Image from the IVF Quenchotest brochure

Calibration of the quenching
media in SYSWELD
Computed
(red) and
measured
(blue)
temperature Cooling
rates
Computed
characteristics of
Heat the quenching
Exchange media
Coefficient
Fitting
Wizard

Calibration of the Diffusion
Case Hardening

Description of the process
Carburization for 6 hours at 1.05%C, at 930°C

Carburization for 3 hours at 0.7%C, at 830°C
Goals
Fast carburization process
Highest hardness at the surface will be reached after grinding
The highest hardness is not at the surface after carburization
%C T(°C)
Temperature evolution
Atmosphere evolution in the atmosphere over
over time time
s s

The highest influence of the carbon evolution in the part

has the temperature in the carburized layers
In case the temperature and carbon concentration

evolution in the atmosphere is known, the carburization
can be precisely adjusted in the simulation
To do so, a carbon adjustment utility is used

Carbon profile evolution through
thickness – 1D specimen
After 1 hour
After 6 hours
After 9 hours
1D Diffusion Calibrator

Set and Run of the Simulation
Heat Treatment Advisor

What is needed to set up and run a
simulation
Mesh
A group of elements that represents the diffusion surface – DIFFUSION
A group of elements that represents the quenched surface –
QUENCHED
A group of elements that represents the part – VOLUME
Material
A material database that contains the calibrated material data
Process
A quenching media database that contains the calibrated quenching
media
The description of the process

Groups illustration
Courtesy: VCST
Group VOLUME –
Material (green)
Group QUENCHED and
DIFFUSION - Diffusion and
quenched surface (red)

The Heat Treatment Advisor
Set up of the
simulation
with one
simple
dialogue box
– The Heat
Treatment
Wizard

Tools for Heat Treatment
simulation
The Heat Treatment Advisor
An easy-to-use Graphical User Interface to facilitate the efficient set-up of Heat Treatment
simulations
The Heat Treatment Advisor includes

The Heat Treatment Wizard
An efficient tool to set up case, through and surface hardening simulations
The Diffusion Wizard
An efficient tool to set diffusion simulations
The Heat Transfer Coefficient Wizard
An engineering tool for the determination of the Heat Transfer Coefficient from time-temperature measurements on a
dedicated specimen
The Hardness Simulation Wizard
An engineering tool for the determination of the hardness after heat treatment
The Metallurgical Parameters Fitting Tool
A tool to fit the metallurgical parameters of phase transformations during heat treatment
The Material Databases and Material Data management in Excel
For heat treatment simulation engineering that incorporates the major materials used in the Industry
The Check Box
A tool to check simulation projects set up with the Heat Treatment Wizard

Winning Points
Differentiation to Competition

Engineering Guide
Together with the

software comes a huge
engineering guide
We know how to get it

right!

Extended documentation
Including Advanced Simulation Engineering Knowledge

Advisor technology – ease of
use
Set up and check of a project with 2 boxes
Fully automatic solver

Why parabolic elements -
result quality aspects
1 linear element 1 quadratic element 4 linear elements
•Solution of a linear steady state problem using 1 linear, 1 quadratic and 4 linear
elements
•Source: ‘The Finite Element Method in Heat Transfer Analysis’, R.W. Lewis
The analytical solution of a steady state or transient thermal problem is

neither linear nor quadratic
The quadratic elements fit much better to the real solution
It lies on hands that quadratic elements can provide with a much coarser
mesh a better result quality then linear elements

Feasible model sizes
Diffusion: 1.000.000 nodes (1DOF) Reasonable 2D

models take
Thermo-Metallurgy: 1.000.000 nodes (1DOF)
usually only 5
Mechanics: 250.000 nodes (3DOF) to 15 minutes
These model sizes fit in 2GB RAM and
computations are done within 1-4 days
•PC
•2GB RAM
•3GhZ
•200GB Hard-Disk

Mixing of different element
types
The mixing of element

types combined with
specific meshing
techniques allows huge
models

Fast and simple heat source
method for surface heat treatment

Advanced Post-simulations
SYSWELD has all capabilities of a nonlinear FEM

program
External loads
Constraints
….
An intelligent interface to SYSTUS and ABAQUS exists

Computed results from the Simulation World of phase
transformations are transferred to the Simulation World without
phase transformations
A material data deck is generated based on the computed
results of SYSWELD
A restart can be performed based on the results computed in
SYSWELD

Available Simulation Methodologies
Surface Heat Treatment, Case Hardening, Through

Hardening

Induction heat treatment
Inductor
Part
Current flow

Induced eddy currents in A in the part, Current
flow in the inductor, moment shot
Penetration depth as a function of the

temperature

Heat source method for surface
heat treatment
Temperature Distortion and

field before residual stresses
quenching after quenching
Distortion before Martensite after

quenching quenching

Aluminum quenching -
distorted structure

Case hardening simulation
methods
Layer based method:

Assumed average
carbon values and
derived layer
thickness
0.2mm
0.35mm
0.25mm Diffusion based
method: Diffusion
simulation

Layer based method

Diffusion based method
150.000 nodes
110 mm Carbon enrichment

Part distortion
Highly amplified
Courtesy: VCST

Training Courses
Heat Treatment

Training courses
Heat Treatment simulation engineering – Getting it

right
Understanding the background – Material data

calibration
Understanding numerical parameters
How to perform and document projects in an effective

manner

Service Offer
Analysis of Details – Risk Assessment – Distortion

Engineering

As service-provider, ESI Group
offers to you
Simulation of distortion and validation of measures to reduce / avoid it
Equalization of distortion – simulation of a negative shape which gives after heat treatment the
planned measurements
Comparison of different designs / carburization profiles / quenching media and evaluation of the
best variant
Comparison of design details and evaluation of the best variant
Consequences of covers when carburizing
Precise prediction of the core hardness
Assessment of process parameters for the production planning
Prediction of places with critical stresses and stress gradients, also during the quenching process
Especially for large parts: Prediction of places with maximum tensile stresses
Prediction of dangerous plastic strains in austenite and martensite
Complete automation of the simulation of hardness, distortion and residual stresses for shafts,
axles and rings
Simulation of the heat effects of welding for engine and power train components
Optimization of process parameters and design details for welding joints of power train and
engine components

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The Heat Treatment Simulation

Solution from ESI GROUP

Copyright © ESI Group, 2006. All rights reserved.

Whilst this document has been carefully written and subject to

The content of this document is an intellectual property of ESI

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Diffusion - Precipitations Mechanical Analysis

Copyright © ESI Group, 2006. All rights reserved.

• Carbon content Metallurgy

• Carbon content Heat transfer

CARBURIZING HEAT TREATMENT

Copyright © ESI Group, 2006. All rights reserved.

martensitic Carbides dissolution

The more carbon

200 400 600 800 1000 1200 temperature

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

The major influence of the result quality do have

The mesh – a dedicated layered mesh is mandatory

Powerful element formulations

The quenching media

The thermal conductivity

The phase transformations

The thermal strains

The yield stress of Austenite

The yield stress of Bainite

Copyright © ESI Group, 2006. All rights reserved.

h⋅L h: Heat transfer coefficient

Bi = L: Half of the thickness of the wall

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Quenching requires a particular layered mesh

To generate layered meshes in 2D and 3D, Visual Mesh includes particular

Without particular layered mesh

Set up and start of a quenching simulation

This takes in SYSWELD only a few minutes

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Without dedicated meshing tool, any heat treatment simulation tool

The Heat Treatment Simulation Solution from ESI includes

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

All CCT diagrams could be by default ‘improved’

The safe way to proceed is

Copyright © ESI Group, 2006. All rights reserved.

Distance from surface in mm

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

• The shape is well reflected

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.

Copyright © ESI Group, 2006. All rights reserved.