FEM simulation of quenching process in A357 aluminum alloy cylindrical bars and reduction of quench residual stress through cold stretching process

• Published in: Computational materials science Vol. 69; pp. 396 - 413
• Main Authors: Yang, Xiawei, Zhu, Jingchuan, Nong, Zhisheng, Lai, Zhonghong, He, Dong
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 01-03-2013; Elsevier
• Subjects: A357 aluminum alloy; Applied sciences; Cold stretching process; Exact sciences and technology; FEM simulation; Hardening. Tempering; Heat treatment; Metals. Metallurgy; Production techniques; Quenching process; Residual stresses; A357 aluminum alloy; Quenching process; Residual stresses; FEM simulation; Cold stretching process; Temperature distribution; Aluminium base alloys; Water quenching; Cold drawing; Aspect ratio; Cylindrical shape; Quenching; Finite element method; Residual stress; Heat transfer
• ISSN: 0927-0256; 1879-0801
• DOI: 10.1016/j.commatsci.2012.11.024

► A FEM model for predicting residual stress of quenched cylindrical bars was created. ► A FEM model for residual stress reduction of quenched cylindrical bars was created. ► Heat transfer coefficient of water were accurately calculated. ► Proper quenching water temperature and cold stretching parameters were selected. ► Effect of aspect ratio of cylindrical bar on residual stress reduction was studied.
The quenching process of A357 aluminum alloy cylindrical bars with 80mm diameter and with heights of 40, 80, 120, 160, 200 and 240mm were investigated by using finite element method (FEM) simulation. Heat transfer coefficient was accurately calculated by using a traditional method of inverse heat transfer. Residual stresses caused by quenching of A357 alloy cylindrical bars are inevitable. Residual stresses reduction through cold stretching process was studied by using FEM simulation. Three numerical examples were used to illustrate the accuracy and efficiency of our method. The results show that this quenching model is able to predict the residual stress with high precision. The influence of some factors (quenching water temperature, aspect ratio of cylindrical bar, pre-stretching ratio and stretching rate) on the residual stress of quenched cylindrical bars after cold stretching was investigated.