Integrated Modeling of Carburizing-Quenching-Tempering of Steel Gears for an ICME Framework

In order to leverage the concept of integrated computational materials engineering (ICME) for manufacturing of high-performance automotive transmission components such as steel gears, it is important to bring a closer collaboration between geometrical design, material selection, and manufacturing design stages for these components. This can be achieved by making the manufacturers aware of the implications of the decisions taken during each of these stages on material and its underlying microstructure. In order to facilitate this, it is necessary to model the evolution of the microstructure in the process-chain and its resultant properties. With this view, the current work focusses on development of an integrated modeling scheme of carburizing, quenching, and tempering processes using chemical composition-dependent, microstructure-based models intended to be used in an ICME framework for steel gear manufacturing. The individual process models are implemented in the commercial FEM suite ABAQUS™, with essential microstructure physics incorporated via user-subroutines. The individual process-models and their sequential integration are validated against experimental case-studies from literature. After validation, the integrated modeling scheme is automated by writing appropriate pre-processing and post-processing wrapper scripts, leading to the development of an independent manufacturing module that can be used in an ICME workflow. Finally, the utility of this module is demonstrated by using it for the exploration of the manufacturing process design and material selection scenarios for the production of a typical spur gear.