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Flow Conditioning in Heat Treatment by Gas and Spray Quenching

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Flow Conditioning in Heat Treatment by Gas and Spray Quenching Flow Conditioning in Heat Treatment by Gas and Spray Quenching Strömungsanpassung in der Wärmebehandlung mittels Gas- und Sprayabschreckung Dem Fachbereich Produktionstechnik der Universität Bremen zur Erlangung des Grades Doktor-Ingenieur vorgelegte Dissertation von M.Eng. Thibaud Bucquet Gutachter: Prof. Dr.-Ing. habil. Udo Fritsching Univ.-Prof. Dr.-Ing. habil. Olaf Keßler, Universität Rostock Tag der mündlichen Prüfung: 12.05.2017 2 “Il semble que la perfection soit atteinte non quand il n'y a plus rien à ajouter, mais quand il n'y a plus rien à retrancher.” - Antoine de Saint-Exupéry 3 Acknowledgments First of all, I would like to express my profound gratitude to Prof. Udo Fritsching for believing in my capacity to complete this work and for the continuous support that truly embodied the definition of a Doktorvater. I am grateful for the trust and responsibility he invested in me, and for the more informal moments spent outside of work or during conferences. I am also grateful to Prof. Olaf Keßler and Prof. Carsten Heinzel for supervising my work and defense, and for the editorial advices and the collaborative research works done together. I have countless great memories from my time at IWT Bremen, and especially thank my colleagues from the VT department for the (working) days and (dancing) nights spent altogether. I am very glad I could count anytime on my Wohngemeinschaft during its various occupancy, as a lively place to meet friends and colleagues. Same goes for Lift, which, besides being an Internet Café, is still like my second living room. Finally, I am thankful I could continue developing my passion for music, along my colleagues, friends, and family, who have constantly been supporting my choices, with all the ups and downs. 4 Abstract Gas quenching has been known for centuries as a convenient, affordable method to heat treat ferrous alloys. Heated parts are taken out of the furnace and quenched at ambient pressure, casually using a blower to increase the heat exchange. Technical developments in the metal industry, over the last decades, have seen a constant improvement of the ratio of heat exchange, e.g. by using pressured chambers, specific blowers, and a variety of gases and gas mixtures. The current gas quenching technologies are adapted to heat treatable metals found in the automotive industry, requesting a minimum heat exchange ratio, also depending on the part geometry. Little has been however investigated concerning the quenched batch, defined as the arrangement of the heated parts onto a single- or multiple-layer charge carrier. The present work, through a combination of experimental and numerical techniques, provides guidelines to adapt the batch to a specific gas flow pattern (spatial fitting), and to adapt the gas flow pattern to the batch structure (temporal fitting). Measurement techniques have been developed to assess the flow patterns inside industrial quenching chambers. Evaluated flow structures have been converted to numerical boundary conditions for extended simulations tools. Simulations have helped implementing technical solutions for flow correction in industrial gas quenching chambers. Furthermore, simulations have served the design of batches of various geometries, to improve both quenching homogeneity and intensity. Both experimental and numerical results confirmed the advantages of gas quenching for the homogeneous heat treatment of automotive steel grades, and demonstrated the potential of various flow correcting devices, such as perforated plates and cylindrical flow ducts. Heat treatment gas and spray quenching has also been integrated into the forging and the turning process chains of single components, successfully optimizing the lean process flow (automation, quality, and time), for various high-performance materials and part geometries. 5 Kurzfassung Die Gasabschreckung ist seit vielen Jahrzehnten als eine bequeme und kostengünstige Methode in der Wärmebehandlung von Metallen bekannt. Erhitzte Teile werden bei Umgebungsdruck z.B. mit Luft abgeschreckt, gegebenenfalls mit einer Erhöhung des Wärmeaustauschs mittels eines Gebläses. Technische Entwicklungen in den letzten Jahrzehnten legen Verbesserungen der Effizienz des Wärmeaustausches dar, z.B. durch Druckkammern unter Verwendung spezifischer Ventilatoren, oder einer Vielzahl von verwendeten Gasen und Gasgemischen. Die heutigen Technologien der Gasabschreckung werden z. B. in der Wärmebehandlung von Metallteilen aus der Automobilindustrie verwendet, wobei eine minimale Intensität des Wärmeaustauschs, in Abhängigkeit von der Teilegeometrie, erforderlich ist. Es wurde jedoch wenig im Bereich von abzuschreckenden Chargen, definiert als die Anordnung der erwärmten Teile auf einem ein- oder mehrlagigen Chargenträger, untersucht. Durch eine Kombination von experimentellen und numerischen Methoden werden in der vorliegenden Dissertation Richtlinien abgeleitet, um die Charge an eine bestimmte Gasströmungsverteilung (räumliche Anpassung) sowie die Gasströmungsverteilung zur Chargenanordnung (zeitliche Anpassung) anzupassen. Geeignete Messmethoden wurden hierbei angewendet, um die Strömungsstruktur innerhalb von Gasabschreckkammern auswerten zu können. Die so abgeleiteten Strömungsstrukturen wurden in erweiterte Simulationstools als numerische Randbedingungen implementiert. Simulationen helfen bei der Umsetzung technischer Lösungen für die Strömungsanpassung in industriellen Gasabschreckkammern. Darüber hinaus unterstützen Simulationen bei der Gestaltung von Chargen aus verschiedenen Bauteil-Geometrien, was sowohl zur Verbesserung der Abschreck-Homogenität als auch -Intensität führt. Die experimentellen und numerischen Ergebnisse in dieser Arbeit bestätigen den Vorteil der Gasabschreckung für eine homogene Wärmebehandlung von Automobilstahllegierungen und zeigen das Potential der verschiedenen Strömungskorrektureinrichtungen, wie Lochblechböden und zylindrischen Führungselementen. Methoden des Gas- und Spay-Abschreckens wurden in Schmiede- und Bearbeitungsprozesse einzelner Komponenten implementiert, durch eine erfolgreiche Lean-Prozessoptimierung (Automatisierung, Qualität und Zeit) für verschiedene Hochleistungswerkstoffe und Bauteil-Geometrien. 6 Selbstständigkeitserklärung Hiermit erkläre ich, dass ich die vorliegende Dissertation selbstständig verfasst und keine anderen als die angegebenen Quellen und Hilfsmittel benutzt und die den benutzten Werken wörtlich oder inhaltlich entnommenen Stellen als solche kenntlich gemacht habe. Diese Arbeit wurde nicht vorher an anderer Stelle eingereicht. Bremen, den Thibaud Bucquet 7 8 1 Table of contents 1 Introduction .................................................................................................................................. 15 2 Motivation and Aims ................................................................................................................... 17 3 State of the art ............................................................................................................................. 19 3.1 Heat treatment of metal alloys .......................................................................................... 19 3.1.1 Steel .............................................................................................................................. 19 3.1.2 Quenchants ................................................................................................................. 23 3.2 Heat treatment gas quenching.......................................................................................... 27 3.2.1 Parameter analysis ..................................................................................................... 27 3.2.2 Workpieces .................................................................................................................. 30 3.2.3 Medium ......................................................................................................................... 34 3.2.4 Quenching unit ............................................................................................................ 36 3.2.5 Batch ............................................................................................................................. 43 3.2.6 Process classification ................................................................................................. 45 3.3 Heat treatment spray quenching ...................................................................................... 51 3.3.1 Parameters .................................................................................................................. 52 3.3.2 Range of applications ................................................................................................. 52 3.4 Gas flow and heat transfer in quenching processes ..................................................... 54 3.4.1 Characteristic physical values and numbers .......................................................... 54 3.4.2 Flow structures ............................................................................................................ 59 3.4.3 Heat transfer in spray quenching ............................................................................. 71 4 Measurements and numerical methods .................................................................................. 75 4.1 Measurement conditions ................................................................................................... 75 4.1.1 Workpiece geometries and materials .....................................................................
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