The document summarizes the simulation of gas quenching of a carburized pinion gear. Different heat transfer coefficients were applied to three zones of the gear to predict temperature profiles, residual stresses, phase distributions, and hardness profiles. The simulation results matched measured temperature data and predicted distortion of 0.0213mm radially after quenching.

1. Gas quenching of CARBURIZED PINION GEAR Prediction of Carbon profile

2. Determination of Heat Transfer Coefficients

3. Prediction of Quenched residual Stress State, Metallurgical Phase distribution & Hardness Profile

4. Prediction of distortionUpwind Technology Inc.6660 Cobb DriveSterling heights, MI 48033586-977-1967

6. Total number of nodes = 22440Total number of elements = 19890The single tooth is divided into three zones. Different heat transfer coefficients are applied on individual zones. Top zone surfaceMiddle zone surfaceBottom zone surface

7. The ambient temperature vs. time was taken from experimentsTemperature vs. time from thermocouples for each zone were used as the baseline for fittingBecause gas quenching was performed, a constant heat transfer coefficient value was assumed for each zone. Iteration to determine appropriate heat transfer values for the three zones was automated using an optimization methodology. Top zone surfaceMiddle zone surfaceBottom zone surface

8. Fitted Heat Transfer CoefficientsAgreement between measured and predicted temperature-time is acceptable for these heat transfer coefficient values.

9. Predicted Minimum Principal StressUnit (mpa)