On the Development of Computational Fluid Dynamics Quenching Simulation Methodology for Effective Thermal Residual Stress Control

• Published in: Journal of materials engineering and performance 2024-04, Vol.33 (8), p.3986-4010
• Main Authors: Jan, James, MacKenzie, D. Scott
• Format: Article
• Language: English
• Subjects: Characterization and Evaluation of Materials; Chemistry and Materials Science; Corrosion and Coatings; Engineering Design; Materials Science; Original Research Article; Quality Control; Reliability; Safety and Risk; Tribology
• ISSN: 1059-9495; 1544-1024
• DOI: 10.1007/s11665-023-09106-7

Heat treatment is a common manufacturing process in the automotive industry used to produce high-performance metal components such as aluminum cylinder heads and steel gear sets. While a heat treatment schedule incorporating a quenching cycle, either through high-velocity air flow or immersion in liquids, can yield parts with durable mechanical properties, an unintended consequence of the intense quenching process is the introduction of thermal residual stress. This stress often is identified as a leading cause for quality issues related to high-cycle fatigue in aluminum engine components or geometric distortion in steel gear sets. Since thermal residual stress is caused by uneven cooling of the materials within the parts, an effective strategy for controlling thermal residual stress would involve directly managing the quenching processes. By reducing the temperature gradient inside the parts during quenching, the quality issues can be improved. Prior to the advent of computer simulation technology, the choice of quench media and the design of quenching recipes were often based on intuitive engineering judgment at best and trial-and-error iterative methods at worst. With the advancements in computational fluid dynamics (CFD) methodology, the quenching process can now be modeled through computer simulations for accurate calculation of temperature profiles and cooling histories of quenched parts. While CFD methods have the potential to manage quenching processes and mitigate thermal residual stress, it is important to note that CFD methods are not a one-size-fits-all solution for all quenching problems. Different quenching processes require different simulation strategies. Furthermore, CFD methods still require calibration and validation before they can be effectively utilized as virtual engineering tools, replacing traditional physical tryouts and experimental methods. The objective of this paper is to develop quenching simulation methodologies that can accommodate various heat treatment requirements and be used to optimize quenching processes, thereby managing quality concerns associated with thermal residual stress. While this research focuses only on two common quenching methods in engine component manufacturing, namely air quenching and water quenching for aluminum components, the principles and methodologies can be extended to other quenching methods based on convective motion of quenching media. Additionally, this research includes the parameterizatio