Three-Dimensional Finite-Element Analysis of the Quenching Process of Plain-Carbon Steel with Phase Transformation

In this study, three-dimensional finite-element (FE) analyses were carried out to predict the volume fractions of various phases generated during the quenching process of plain-carbon steel and the temperature history, considering the latent heat generated due to phase transformation. Diffusional phase transformation for a nonisothermal process was described by discretizing the cooling curve into various small isothermal steps and using a time-temperature-transformation (TTT) diagram for carbon steel. For this, Sheil’s additive rule was adopted to predict the incubation time which indicates the onset of phase nucleation, and, also, the Johnson–Mehl–Avrami–Kolmogorov (JMAK) equation was used to model the phase growth. For handling diffusionless transformation, Koistinen and Marburger’s equation was employed to model the austenite-martensite transformation during the rapid quenching process. Finally, temperature variations obtained from the FE simulation were compared to the experimental data available in the literature to validate the reliability of the numerical solution, and its application was made to simulate the three-dimensional forming process of a bevel gear and cam lobe.