Abstract
To improve the comprehensive performance of high speed steel (HSS) cold rolls, the induction hardening processes were analyzed by numerical simulation and experimental research. Firstly, a modified martensitic phase transformation (MMPT) model of the tested steel under stress constraints was established. Then, the MMPT model was fed into DEFORM to simulate the induction quenching processes of working rolls based on an orthogonal test design and the optimal dual frequency of the induction quenching process was obtained. The results indicate that the depth of the roll’s hardened layer increases by 32.5% and the axial residual tensile stress also becomes acceptable under the optimized process. This study provides guidance for studying phase transformation laws under stress constraints and the optimization of complex processes in an efficient manner.
Highlights
Work rolls of cold rolling, requiring high surface hardness, good thermal shock resistance, anti-stripping ability, and wear resistance, are usually produced using high carbon and high-alloy forged steel, such as Cr8 [1], D2 cold work tool steel [2], semi-highspeed steel (SHSS) [3], high speed steel (HSS) [4,5], etc
Thermal stresses and martensitic transformation stresses caused by volume expansion during the cooling process of rolls lead to large tensile stress locally and even quenching cracking [6,7,8,9]
Based on the martensite phase model obtained in this work, the dual frequency induction hardening processes listed in Table 2 were simulated using DEFORM-3D software, which allowed the parameters in Equation (1) to be input and modified
Summary
Work rolls of cold rolling, requiring high surface hardness, good thermal shock resistance, anti-stripping ability, and wear resistance, are usually produced using high carbon and high-alloy forged steel, such as Cr8 [1], D2 cold work tool steel [2], semi-highspeed steel (SHSS) [3], high speed steel (HSS) [4,5], etc. The impact of stress on martensite phase transformation can be neglected; the above models and methods of austenite–martensite phase transformation are applicable. The volume expansion caused by martensitic transformation leads to compressive stress in the phase change layer and tensile stress inside the workpiece. Basak and Levitas presented a finite element procedure for a new phase field approach to multivariant martensitic transformations at large strains and with interfacial stresses induced by temperature and stress [13]. Liu et al systematically studied the impact of uniaxial compressive stress on the kinetics of the austenite–martensite transformation and presented a modular phase-transformation model [15]. The dual frequency induction hardening processes were systematically studied using numerical simulations and experiments, based on an orthogonal experimental design.
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