We are discussing here intensive quenching processes: IQ-2 and IQ-3 technologies. The IQ-2 technology requires the duration of transient nucleate boiling process evaluation during batch quenching. The IQ-3 technology requires the duration of cooling process evaluation during single part quenching when direct convection is provided to achieve maximal compressive residual stresses at the surface of steel parts after quenching. During batch quenching from high temperatures (800oC - 900oC) in cold liquids a local film boiling can appear which is a reason for big distortion and crack formation. Presence of local film boiling and crack formation should be controlled by special system which we call a "Smart Robot" . It will be able to correct developed recipes of quenching processes. Any idea in this field is greatly appreciated.
Are ultrasound vibrations or another external actuation available to affect the local boiling film and change thermal and mechanical state of subsurface layer of steel part?
Yes, we exactly know frequency and intensity of noise of transient nucleate boiling process and we don,t know exactly the frequency of local film boiling. The local film boiling is a reason for big distortion, crack formation and non- smoothness of hardness distribution on the surface of quenched steel parts. Also, we don't know exactly the frequencies of typical industrial noise which should be filtered. A role of local film boiling on distortion you can find in the publication: N.I.Kobasko, M.A.Aronov, B.L.Ferguson, Z.Li, "Local Film Boiling and Its Impact on Distortion of Spur Gears During Batch Quenching", Materials Performance and Characterization, Vol. 1, No. 1, pp. 1-15, 2012, ISSN: 2165-3992.
The "Smart Robot" for monitoring quenching processes can be designed and manufactured and is very realistic if we know exactly:
1. What are frequencies and intensity of noise generated by nucleate boiling process?
2. What are frequencies and intensity of noise of local and full film boiling?
3. What are frequencies and intensity of noise generated by crack formation?
4. What are frequencies and intensity of industrial noise which should be filtered?
Mentioned above problems should be solved experimentally which are rather costly.
Industrial companies are interested in final results, namely in "Smart Robot" and not in academic investigations 1-4.
The "Smart Robot" is needed to provide high quality of intensively quenched steel parts, prevent in all condition of intensive quenching crack formation and provide minimum distortion after intensive quenching, and also inform engineers on possible failures.
Dear Nicolai, "Smart Robot" is a good idea (although each robot is smart machine in accordance with definition). As I am understanding, you are need in feed back development which allow us to optimize quenching process having in a mind minimun cracking and distortiong. So, the thermomechanical model of thermal treatment will be useful as a base for writing software which will be operating in real time.
Serge
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