The "State of the Art" in Heat Treat Simulation
Solver improvements allow models with millions of elements to run on desktop computers. Larger models have done wonders for solution accuracy. Meshing techniques allow users to refine regions, such as the surface of gear teeth that will be carburized. Rotational symmetry is frequently used to further refine many models. Sources for quality material properties have increased over the years. Tools to approximate required data based on chemistry are available and maturing. Heating models, including radiant, convective, electrical resistance and induction are integrated in to heat treat simulation systems. Production examples of various heating models will be presented. Integrated simulation systems include forming to capture the effects of forging, coining or other mechanical processes on the microstructure.
The future includes the use of DOE and Optimization in heat treat simulation. How companies will model the entire process chain to build a more accurate fatigue model for the part in service will be discussed. In terms of TRL (technology readiness level), heat treat simulation was in the 2–3 range in the 1990’s and is moving quickly to 7-8.