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UniCase Master®

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Precision Case Hardening for High-Volume Production with Distortion Control

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UniCase Master®

  1. 1. 20171021 Production with Distortion Control Precision Case Hardening for High-Volume
  2. 2. AN ADVANCED TECHNOLOGY SOLUTION FOR MANUFACTURING The UniCase Master ® (Source: SECO/WARWICK)
  3. 3. BENEFITS IN COMPARISON TO TRADITIONAL ATMOSPHERE TECHNOLOGY / In-line manufacturing / Elimination batch material handling costs & time / Enhanced process precision, quality & repeatability / Less overall distortion / Improved distortion control / High productivity, fast throughput / Superior surface quality / No intergranular oxidation (IGO) / Reduced utility consumption / No quenching oil and post-washing / Safety, no open flame, no risk of fire or explosion / Clean, environmentally friendly process / System flexibility & adaptability A few of the many UniCase Master ® benefits to industry include: (Source: SECO/WARWICK)
  4. 4. CASE HARDENING BY CARBURIZING / Carburizing is a thermo-chemical process in which carbon is introduced into the surface of a component part followed by rapid quenching, which results in a hard and wear resistant surface and a soft, ductile core. / Used in applications requiring enhanced surface properties (wear, abrasion) are needed such as in power transmission applications for drive system components such as gears, shafts, and bearings to name a few. / A typical requirement for case hardening is: Surface hardness 58 - 62 HRC Effective Case Depth 0,4 – 2 mm at 550 HV (52,5 HRC) 0.015 – 0.08” at 50 HRC (513 HV) (Source: SECO/WARWICK; www.shanthigears.com/product s/loose-gears/ )
  5. 5. TRADITIONAL TECHNOLOGY SOLUTIONS - / Endothermic atmosphere or nitrogen/methanol carburizing / Quenching in oil / Large footprint installations (Source: SECO/WARWICK) ATHMOSPERE FURNACES & SALT BATH EQUIPMENT
  6. 6. TRADITIONAL HEAT TREATMENT / Each piece in the load is exposed to a different heat treatment, depending on its position in the batch in terms of temperature, carburizing case depth and hardness after quenching. The result is high variability and poor repeatability. / Quenching is directional (2D) creating temperature gradients and a large amount of thermal distortion. The result is a large amount of thermal distortion. (Source: SECO/WARWICK) BATCH EXAMPLES
  7. 7. TRADITIONAL TECHNOLOGY / Uncontrolled distortion and poor repeatability / High material handling costs Low process and operation flexibility Inability to monitor single pieces Intergranular oxidation / Cost of fixtures Cost of maintenance Costs of waste neutralization Risk of fire and explosion Environmental issues (Source: SECO/WARWICK) DISADVANTAGES
  8. 8. MODERN TECHNOLOGY SOLUTION (Source: SECO/WARWICK) VACUUM FURNACES FOR CASE HARDENING (LPC+HPGQ/OIL)
  9. 9. LOW PRESSURE CARBURIZING + HIGH PRESSURE GAS QUENCH / More accurate process results re: uniformity & quality / Less quenching distortion / Fast, high temperature carburizing / No intergranular oxidation / Ideal surface quality / Reduction of energy and process gases consumption & emission / Elimination of oil, washer and washing fluids / Safe, no open flame, no risk of fire or explosion / Clean and environmentally friendly (Source: SECO/WARWICK)
  10. 10. COMMON PARTS HANDLING - A BATCH SOLUTION Result = function of [time (t), temperature (T), atmosphere (C), quenching (Q)] t(2), T(2), C(2), Q(2) t(3), T(3), C(3), Q(3) t(1), T(1), C(1), Q(1) t(1) ≠ t(2) ≠ t(3) T(1) ≠ T(2) ≠ T(3) C(1) ≠ C(2) ≠ C(3) Q(1) ≠ Q(2) ≠ Q(3) ECD(1) ≠ ECD(2) ≠ ECD(3) 0,6 – 1,1 mm 0.020 – 0.040” (Wide case depth variation / tolerances)
  11. 11. DISTORTION – UNI-DIRECTIONAL COOLING Directional cooling ≠ even gas stream Uniform gas stream ≠ uniform cooling Uniform cooling ≠ lower distortion BATCH GAS INFLOW GAS OUTFLOW ONE SIDE COOLING Even gas flow does not guarantee uniform cooling of part Uniform cooling does not mean lower distortion Directional cooling does not ensure even gas flow in the entire working space (Source: SECO/WARWICK)
  12. 12. DISTORTION – UNI-DIRECTIONAL COOLING TEMPERATURE GRADIENT = DISTORTION NITROGEN 20 BAR, 15 m/s GAS FLOW: TOP TO BOTTOM ΔT ≈ 500oC ΔT ≈ 930oF (Source: SECO/WARWICK)
  13. 13. IS THE BATCH HANDLING THE ONLY SYSTEM ? 3 (Source: SECO/WARWICK)
  14. 14. Precision Case Hardening using a Single Piece Flow with Low Pressure Carburizing & 4D Quenching® 2017
  15. 15. LEAN MANUFACTURING Heat treatment integration into continuous manufacturing production lines (Source: SECO/WARWICK)
  16. 16. PROCESS FLOWCHART – 100% TRACEABILITY GREEN PARTS PRE-WASH INDIVIDUAL PART IDENTIFICATION PRECISION CASE HARDENING BY LOW PRESSURE CARBURIZING & 4D QUENCHING® POST COOLING/FREEZING TEMPERING POST COOLING NON-DESTRUCTIVE TESTING NEXT STEP REVOLUTIONARYINNOVATION UniCaseMaster®System SINGLEPIECEFLOW (Source: SECO/WARWICK)
  17. 17. UniCase Master ® – INSTALLATION OVERVIEW H3,5m(11,5ft) (Source: SECO/WARWICK) CONSUMTION: • Power 150 kW • Nitrogen 20 kg/h • Acetylene 30 dm3/min • Water 10 m3/h
  18. 18. 8 • Gear dia. 200 mm (8.0”) • Height 50 mm (2.0”) • Gear mass 4 kg (9 lbs) • Number of positions 15 (per process chamber) • Tact time 30 sec. • Temperature 1100oC (2000oF) • Uniformity +/- 5oC (10oF) • LPC FineCarb®, PreNitLPC® • Quenching up to 10 bar N2 UniCase Master ® – SPECIFICATION (Source: SECO/WARWICK)
  19. 19. UniCase Master ®– SINGLE-PIECE FLOW – HEAT-UP IN LPCDIFFUSION ELEVATOR 4D QUENCHING ® ELEVATOR HEAT-UP (Source: SECO/WARWICK)
  20. 20. HEAT-UP IN HEAT-UP CHAMBER (1) Heating curve by radiation, CFD simulation for a single gear, dia. 190 mm / 7.5” , 3,0 kg / 6.6 lbs, ε = 0,35 (Source: SECO/WARWICK)
  21. 21. UniCase Master ®– SINGLE-PIECE FLOW – LPC IN ELEVATOR 4D QUENCHING ® ELEVATOR HEAT-UP LPCDIFFUSION (Source: SECO/WARWICK)
  22. 22. UniCase Master ®– SINGLE-PIECE FLOW – DIFFUSION IN LPC ELEVATOR 4D QUENCHING ® ELEVATOR HEAT-UP LPCDIFFUSION (Source: SECO/WARWICK)
  23. 23. FINAL CARBON PROFILE AFTER DIFFUSION 30 min total process time (LPC and diffusion at 1040oC / 1900oF) (Source: SECO/WARWICK)
  24. 24. UniCase Master ® – SINGLE-PIECE FLOW - QUENCHING IN OUT ELEVATOR 4D QUENCHING ® ELEVATOR HEAT-UP ELEVATOR LPCDIFFUSION (Source: SECO/WARWICK)
  25. 25. UniCase Master ® – 4D QUENCHING® – UNIFORM & EFFICIENT 4D = 3D (cooling gas is delivered by nozzles from all sides) + 1D as the quenched part rotates TRANSFER TO QUENCH / Stationary / Rotation (rpm and direction) / Oscillation (variable angle) / Time depend gas flow Controlled Cooling 00:00:00,000START QUENCH 2 SECONDS 5 SECONDS 9 SECONDS (<500ºC) Minimal Distortion Powerful cooling in 10 bar nitrogen – as fast as oil quenching Heat transfer – 2,000 W/K-m2 Oil He (Source: SECO/WARWICK)
  26. 26. CARBURIZING UNIFORMITY Max 0,595 g Min 0,583 g 2 % PRECISION Extremely uniform carbon absorption within all parts (Source: SECO/WARWICK) Mass increase by carbon absorption in gears 1050ºC (1925ºF) ECD 0.6 mm (0.024”)
  27. 27. CARBURIZING PRECISION 0,8 mm + 0,5 mm 0.032” + 0.20” requirement Target 0,90 mm 0.035” Result 0,90±0,03mm 0.035” ± 0.001” Microhardness – Active Flank (Source: SECO/WARWICK)
  28. 28. 0 10 20 30 40 50 60 70 80 90 100 3D ANALYSIS OF RING GEAR TOOTH FORM TRDITIONAL BATCH GAS QUENCHING Toothformdistortion[%] UniCase Master ®DISTORTION UniCase Master ® INITIAL PROCESS UniCase Master® OPTIMIZED PROCESS / 3-5 times less distortion in comparison to batch HPGQ technology green parts case hardened parts DIA ~180 mm ~7,1” (Source: SECO/WARWICK)
  29. 29. DISTORTION / 2-4 times less distortion (size change and variation) compared to vacuum batch oil quenching UniCase Master ® 200 mm (8”) 120 100 80 60 40 20 0 Distortion[µm] (Source: SECO/WARWICK)
  30. 30. DISTORTION 0 10 20 30 40 50 60 70 80 90 100 INTERNAL GEAR DISTORTION Radial Run-OutAxial Run-Out Fp (Sum of Left & Right) Cumulative Pitch Deviationn Parallelism Distortion[µm] UniCase Master ® green parts case hardened parts Class 7 Class 8 Class 9 Class 7 Class 8 DIA ~160 mm ~6,3” / 2-5 times less distortion in comparison to vacuum batch oil quenching (Source: SECO/WARWICK)
  31. 31. UniCase Master ® – PRODUCTIVITY / Frequency cycle 60 s / Effective case depth 0,6 mm /0.024” / Steel grade 20MnCr5/8620 / Process timing 15 x 60 s - Heating up 15 min - LPC 15 min - Diffusion 15 min 0.5 million/year Gear Diameter 8.0” / 200 mm Time Gear Production 1 minute 1 1 hour 60 8 hours 480 24 hours 1,440 5 days 7,200 1 week 10,080 30 days 43,200 6,500 hours 390,000 7,000 hours 420,000 7,500 hours 450,000 8,000 hours 480,000 1 year 525,600 (Source: SECO/WARWICK)
  32. 32. / Frequency cycle 30 s / Effective case depth 0,6 mm /0.024” / Steel grade 20MnCr5/8620 / Process timing 30 x 30 s - Heating up 15 min - LPC 15 min - Diffusion 15 min UniCase Master ® – PRODUCTIVITY 1 million/year Gear Diameter 4.0” / 100 mm Time Gear Production 1 minute 2 1 hour 120 8 hours 960 24 hours 2,880 5 days 14,400 1 week 20,160 30 days 86,400 6,500 hours 780,000 7,000 hours 840,000 7,500 hours 900,000 8,000 hours 960,000 1 year 1,051,200 (Source: SECO/WARWICK)
  33. 33. THROUGHPUT INCREASE x4 x16 (Source: SECO/WARWICK)
  34. 34. FLEXIBILITY & ADAPTABILITY (MULTIPLE CONFIGURATIONS / PROCESSES) Re-sizing Multi-chamber & multi-position LPC & HPGQ Hardening, LPC, Annealing, Brazing, etc. Single-chamber & multi-position Multi-chamber & single-position Single-chamber & single-position Technology, process, throughput (Source: SECO/WARWICK)
  35. 35. UniCase Master ® – INNOVATION IN CASE HARDENING / Lean manufacturing / High throughput / Low cost • 100% integration into continuous production lines • Zero cost of heat treatment fixtures • Zero cost of logistics involving material handling / Single-piece flow • 10 times improvement in precision & repeatability of results • 100% traceability, individual part monitoring and reporting • 100% single part in-line testing after case hardening / 4D Quenching® • 2 – 4 times less distortion (size change) • 2 – 4 times less distortional variation • 2 – 4 times less hard machining time • Elimination of many post-machining operations / Low Pressure Carburizing / High Pressure Gas Quench • Elimination of IGO / IGA • Elimination of fire and explosion hazards • Clean & environmentally friendly production / System flexibility & adaptability • Operational & technological & process flexibility • Modularity • Multiple configurations (resizing) (Source: SECO/WARWICK)
  36. 36. UniCase Master ® – REVOLUTION IN CASE HARDENING Lean Manufacturing – Single-Piece Flow Distortion Control – 4D Quenching® Flexible & Modular Configuration Industry 4.0 (Source: SECO/WARWICK)
  37. 37. THANK YOU SECO/WARWICK S.A. 8 SOBIESKIEGO STR., 66-200 ŚWIEBODZIN, POLAND WWW.SECOWARWICK.COM Marcin PRZYGOŃSKI Sales Manager / Vacuum Furnaces Division Mob: +48 519 051 635 E-mail: Marcin.Przygonski@secowarwick.com Web: www.secowarwick.com

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