Abstract
The paper is devoted to development of the modelling approach based on 3D finite-element (FE) analysis of the transient temperature fields and the thermally induced phase transformations as a way towards residual stress management in large size forgings. Heating, holding and cooling stages are under consideration and modelling of both the austenite formation and decomposition are taken into account. The thermal-mechanical FE model capable of taking into account changes in the specific volume during ferrite/austenite transformation is coupled with the relevant phase transformation model in order to allow simulation of the transient stresses due to both thermal contraction and the dilatometric effect. The model is capable of taking into account different boundary conditions for the heat transfer problem based on the available data. To improve the predictive abilities, the following two commercial FE codes, such as MSC Marc 2013.1.0 and Abaqus/Standard6.12, are used for solving the non-steady state 3D problem of the metal expansion/contraction during consecutive heating, holding and cooling stages. Although all the mentioned process steps are considered, the model is dedicated to be used for modelling the cooling stages of large forgings and castings.