Numerical Simulation of Full Carburizing Process of an Automotive Gear

Abstract

\n The objective of the paper is to present material and numerical models needed to simulate with accuracy the full carburizing process of an automotive gear. The rough dimensions of the gear studied are 120mm in diameter and 45mm in height. From a numerical standpoint, as the carburizing affects only a thin layer under the surface, the mesh discretization must be adapted. Consequently, anisotropic mesh is used to describe accurately this zone. The temporal discretization must be also adapted to follow carbon diffusion and thermal evolution. The material models represent metallurgical phenomena during the complete carburizing process. The initial heating of the part induces phases transformation due to austenization. Subsequently, while holding at carburizing temperature, boundary conditions are applied to diffuse carbon into the part. While carbon content increases next to the surface, austenitic metallurgical grain growth is also modelled. A final cooling sets the properties of the carburized part. The model takes into account the phase changes using phase transformation diagrams locally adapted to chemical compositions and grain sizes. Simulation is used to predict the in-use properties of the gear at the end of the carburizing process as well as important results such as assessment of distortion and residual stresses. Thermal stresses, volume variation due to phase changes, and transformation plasticity all contribute to establish the final mechanical properties of the part. During the complete process, the material is modelled with an elasto-viscoplastic behavior and mixing methods are used to consider the relative contribution of each phase.