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 Drive Sterling heights, MI 48033 586-977-1967

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

7. The ambient temperature vs. time was taken from experiments Temperature vs. time from thermocouples for each zone were used as the baseline for fitting Because 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 surface Middle zone surface Bottom zone surface

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

9. Predicted Minimum Principal Stress Unit (mpa)

10. AUSTENITE FERRITE L BAINITE MARTENSITE U BAINITE

11. Hardness Distribution

12. Radial distortion contour plot using the local cylindrical coordinate system Radial displacement, 0.0213 mm Radial displacement, 0.121 mm