FEM modeling and experimental validation of quench-induced distortions of large size steel forgings

Industrial-level water quenching operations generally lead to high residual stresses and distortion, especially for large steel parts, due to the high temperature gradient present. In this work, a 3D Finite Element (FE) model was used to simulate the water quenching process of a large size forged block made of high-strength steel in a bid to predict the induced distortion and residual stresses. The FE model considers the coupling between the thermal, mechanical and metallurgical fields and in addition to that the mechanical properties related to each phase at different temperatures were experimentally generated to feed the FE model with reliable material data. Furthermore, an experimental approach was designed to accurately measure the shape change after quenching. The results indicated that the FE model was able to predict the pattern of the distortion induced by the quench process. Also, the value of the maximum magnitude of thickness reduction was predicted at the center region of the block with a deviation of 0.5 mm.