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Proceedings Papers
HT 2021, Heat Treat 2021: Proceedings from the 31st Heat Treating Society Conference and Exposition, 244-256, September 14–16, 2021,
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Computer simulations are increasingly being used in the automotive industry to evaluate the state of stress in cylinder blocks during casting and heat treat processes. With recent advancements, it is now possible to model casting and quenching processes as well as residual stress and high cycle fatigue. However, calculating the final stress in cylinder blocks requires the integration of several software tools with different meshing topologies, numerical methods, data structures, and post-processing capabilities. The intent of this research is to develop an integrated virtual engineering environment that combines casting simulation, computational fluid dynamics, and finite element methods in order to simulate the manufacturing process from the beginning of casting, through water quenching heat treatment, to engine dynamometer testing. The computational environment is built on three CAE tools, Magmasoft, AVL Fire, and Abaqus, and required considerable amounts of research and development to validate each numerical method and the tools that facilitate data exchange between them.
Proceedings Papers
HT2017, Heat Treat 2017: Proceedings from the 29th Heat Treating Society Conference and Exposition, 411-421, October 24–26, 2017,
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Heat treatment is a common manufacturing process in automotive industry to produce high performance components such as cylinder heads and cylinder blocks. Although heat treatment incorporating a quenching process, either by high velocity air flow or water, can produce parts with durable mechanical properties, an unwanted effect of intense quenching processes is that they also induce thermal residual stress, which often is a leading cause for quality issues associated with high cycle fatigues. During product development cycle, it is not uncommon to switch between air and water quench media and change quench orientation in order to minimize residual stress. However, the choice of quench media and quench orientation is often determined by intuitive engineering judgement at best and trial-and-error iterative method at worst. With the advancement of CFD technologies, the temperature profile and history of quenching processes now can be accurately calculated. Since thermal residual stress is directly linked to non-uniform temperature distribution in the metal, spatial temperature gradient of each quenching process is evaluated to study and compare the performance of different quench media and configuration. The conclusion of this study can be used to establish engineering guidelines for future product development.