Novel Multi-Physics-based Modeling of a Quenching Process with Thermal-Metallurgical-Mechanical Interactions in Aluminum Component

J. Lua, Jinhui Yan, A. Karuppiah, Peipei Li, M. Stuebner, Ze Zhao
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引用次数: 2

Abstract

Large aluminum forging parts are increasingly used in aerospace structures to enable structural unitization. In the fabrication of heat treatable aluminum parts for the aerospace industry, quenching is a crucial step to suppress the precipitation to retain the supersaturation of the solid solution, control the distortion, and minimize the residual stress in aluminum alloys. Because of the complex interaction between temperature, phase-transformation, and stress/strain relation that depends on the temperature distribution and the microstructure of the workpiece, there is no performance informed quenching process that can be applied reliably to reduce the high scrap rate of airframe aluminum forging parts with a significant amount of residual stress and distortion. The development of a quicker and more reliable qualification and certification procedure is so important given the stringent constraints on cost and schedule. The primary goal of this study is to develop a multi-physics tool to perform simulations with optimized quenching parameters to achieve minimum distortion. A high-fidelity thermal multi-phase fluid-structure interaction (FSI) model is applied to simulate fluid dynamics and temperature fields in the quenchant tank. The developed immersogeometric modeling approach is used next for an efficient model generation of a 3D workpiece with various dipping orientations. Given the temperature and pressure profiles predicted from the FSI based heat transfer module, residual stress and distortion prediction modules are developed by including temperature and pressure fields mapping and temperature and strain rate dependent property evolution via Abaqus’ userdefined subroutines. Verification and demonstration studies are performed using aluminum coupons dipped into a quenching tank of two different orientations with and without agitation. Time histories of the temperature and residual stress fields were predicted to explore the relationship between the process and performance.
铝件热-金属-机械相互作用淬火过程的多物理模型
大型铝锻件越来越多地用于航空航天结构,以实现结构的统一。在航空航天热处理铝件的制造中,淬火是抑制析出以保持固溶体过饱和、控制变形、减小铝合金残余应力的关键步骤。由于温度、相变和应力/应变关系之间的复杂相互作用取决于温度分布和工件的微观结构,因此没有一种性能可靠的淬火工艺可以用于降低具有大量残余应力和变形的机身铝锻件的高废品率。鉴于对成本和进度的严格限制,开发更快、更可靠的资格和认证程序非常重要。本研究的主要目标是开发一个多物理场工具,以优化淬火参数进行模拟,以实现最小的畸变。采用高保真热多相流固耦合(FSI)模型模拟了淬火槽内的流体力学和温度场。利用所开发的浸入式几何建模方法,对具有不同倾斜方向的三维工件进行了高效的模型生成。根据基于FSI的传热模块预测的温度和压力分布,通过Abaqus用户定义的子程序开发了残余应力和变形预测模块,包括温度和压力场映射以及温度和应变率相关的特性演化。验证和示范研究是用铝卷蘸入两个不同方向的淬火槽中进行的,有和没有搅拌。预测了温度场和残余应力场的时间历程,以探索工艺与性能之间的关系。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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