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# Immersion Quench Process Modeling

DANTE has a feature of using a customized quenching film subroutine for modeling the immersion of a component into a quenchant. This feature can be used for liquid quench immersion process and spray quench process, etc. This feature can also be used to account the quenchant side flow effect for setting up the thermal boundary condition conveniently for out-of-round or oval distortion analysis. This feature is integrated with Abaqus/Standard solver and Ansys/Mechanical solver.

* To use Abaqus/Standard solver, an external file should be prepared in the working directory, called by the film subroutine. The file name is: “***Job\_Name***” + ***“\_FILM-QUENCH.TXT***”, which must be located in the current working directory. For example, if the job name is “Job-1”, then the film subroutine file name would be “**Job-1\_FILM-QUENCH.TXT**”. This file can be generated automatically from the DANTE Plug-In by entering the required information into the Quench Parameters Dialog box. The Quench Parameters Dialog box can be accessed by navigating to the Initial/Boundary Conditions tab in the DANTE Plug-In. The Add Interaction button is chosen, and the Quenching Method box is checked. Linear or Rotational is then chosen as the Quenching Method and the Quench Parameters button is used to open the Quench Parameters Dialog box, as shown in Figure below. This section only describes the Linear option; please see the Rotational Quenching Method section in the Additional Topics of this help file for information on the Rotational option. After all relevant information is entered in the Immersion Quench Parameters Dialog box, OK is selected to close the dialog box and return to the Interactions box.
*

```
<figure><img src="/files/xfCAuL9R4wAgjmdKN3ET" alt=""><figcaption></figcaption></figure>
```

* To use Ansys/Mechanical solver, the immersion quench is defined by the file ***DANTE\_thermal\_FILM-QUENCH.TXT*** file, and this file is generated automatically by ANSYS ACT.

<figure><img src="/files/kJAQyJLZkKG7iEN3RkBj" alt=""><figcaption></figcaption></figure>

The Immersion Quench Parameters Dialog box, shown again in Figure 2, requires the following information for the necessary file to be generated in the working directory:

***Quench Surfaces:*** The surfaces to be quenched must be defined prior to adding the immersion quench interaction; the defined surfaces populate a dropdown list under **Quench Surfaces**. Multiple surfaces can be defined with independent immersion quench parameters;

***Quench Speed*****:** The immersion rate (quench speed) is chosen to be constant (**Constant Quench Speed**) or a function of time (**Quench Speed vs. Time**). All rates must be defined in millimeters per second (mm/s). If the immersion rate is a function of time, the rate must be defined as an Amplitude prior to defining the immersion parameters. Amplitudes are defined from the Add Film Property/Amplitude button under the Initial/Boundary Conditions tab from the DANTE Plug-In.

***Quench Start Time*****:** Generally, the immersion quench step begins with the part just above the surface of the quenchant, with any transfers from furnace to quench tank being handled in another step. If this is the case, the **Quench Start Time** will be 0.0. However, there may be situations which require different surfaces to touch the quenchant at different times, possibly due to the surface’s location on the part relative to the quenchant surface. This parameter can be used to define that type of behavior effectively. All times must be defined in seconds.

* **For example**: If two surfaces, A and B, are defined to be quenched using the immersion user subroutines with a **Quench Start Time** of 0.0 for surface A and a **Quench Start Time** of 2.0 for surface B, then the immersion process for surface B will be delayed by 2.0 seconds relative to surface A. This can occur due to blind holes or tubular assemblies.

***Relative Distance from Part to Quench Start***: The starting line of quench relative to the first point entering the quench (default is 0.0 mm). For a given part geometry (surface definition and meshing information) and an immersion orientation, the first point of the given surface entering the quench tank liquid surface is calculated by the subroutine. Generally, the point will be touching the quenchant at the time zero (with **Relative Distance from Part to Quench Start** being 0.0). If **Relative Distance from Part to Quench Start** equals X (a positive number), then the part (surface) needs to travel X distance with the defined **Quench Speed** along the immersion orientation before the first point of the part touches the surface of the quenchant. This can be useful for tubular assemblies in which the quenchant does not enter certain portions of the assembly until the component is immersed a certain distance. All distances must be defined in millimeters (mm).

***Relative Distance from Quench Start to Quench End***: The ending line of the quench relative to the first point entering into the quench. The region between **Relative Distance from Part to Quench Start** and **Relative Distance from Quench Start to Quench End** is quenched. If **Relative Distance from Quench Start to Quench End** is less than **Relative Distance from Part to Quench Start**, the quenching region is infinite below, meaning the component is fully immersed in the quenchant. This is the most common scenario. Defining a region of quenching is generally only needed for linear spray quenching in which the spray pattern determines the **Relative Distance from Quench Start to Quench End**. All distances must be defined in millimeters (mm).

***Dribble Effect Start Location***: The line to define the residual effect from quenching (i.e. dribbling from linear spray quenching). If the **Dribble Effect Start Location** is less than the **Relative Distance from Quench Start to Quench End**, the region defined is infinite below the **Relative Distance from Quench Start to Quench End**, meaning the entire surface below is subjected to the dribble effect. If the **Dribble Effect Start Location** is greater than the **Relative Distance from Quench Start to Quench End**, the residual cooling from quenchant dribble occurs on the relative distance between the **Relative Distance from Quench Start to Quench End** and the **Dribble Effect Start Location**. This effect is usually only required for immersion spray quenching, where the component is not completely immersed, but has a defined spray zone that travels along the length of the component. This parameter can also be used to describe severe surface agitation which causes quenchant to splash onto the area of the component just above the quenchant surface. All distances must be defined in millimeters (mm).

***Ambient Air Temperature*****:** This is the temperature of the ambient air outside of the quench and dribble zones and is assumed to remain constant. This is a reasonable assumption, as the air surrounding the part should remaining relatively constant since the temperature of the part outside of the quenchant essentially remains at the same temperature. Cooling in air does have an effect on the temperature, but the immersion rate is generally fast enough to avoid significant cooling outside of the quench tank. All temperatures must be defined in °C.

***Ambient Dribble Effect Temperature*****:** This is the temperature of the quenchant in the dribble effect zone and is assumed to remain constant. This is a reasonable assumption, as the temperature differential between the **Ambient Dribble Effect Temperature** and the surface temperature is usually small, restricting any temperature increase which may occur in the fluid to a negligible effect. All temperatures must be defined in °C.

***Ambient Quench Temperature*****:** This is the temperature of the quenchant and is assumed to remain constant. This is a reasonable assumption, as there is generally enough liquid quenchant in the quench tank to avoid significant increases in quenchant temperature. All temperatures must be defined in °C.

***Ambient Air HTC*****:** This is the heat transfer coefficient for the ambient air outside of the quench and dribble effect zones and is assumed to remain constant. This is a reasonable assumption, as convective heat transfer coefficients for gases have been found to remain effectively constant over the temperature range of interest. All heat transfer coefficients must be defined in W/mm²K.

***Ambient Dribble Effect HTC*****:** This is the heat transfer coefficient for the dribble effect zone and is assumed to remain constant. This is a reasonable assumption, as the temperature range witnessed during the cooling from the dribble effect is minimal. This results in a small variation in the HTC and has been found to not significantly affect accuracy. All heat transfer coefficients must be defined in W/mm²K.

***Ambient Quench HTC*****:** This is the heat transfer coefficient for the quenchant and must be defined in terms of temperature. The HTC vs. temperature should be defined as a Film Property prior to defining the immersion quench parameters using the Add Film Property/Amplitude button under the Initial/Boundary Conditions tab in the DANTE Plug-In. The **Ambient Quench HTC** dropdown menu is populated with all HTC vs. temperature Film Properties and as such; even a constant quenchant HTC (like that of spray) must be defined in terms of temperature, with two temperatures defined with the same HTC value. The appropriate Film Property should be selected from the dropdown menu. All heat transfer coefficients must be defined in W/mm²K.

<figure><img src="/files/xKGJL6CR38YSUZVCk8uN" alt=""><figcaption></figcaption></figure>

***Directional Convection Variation***: This parameter can be activated if there is a nonuniform cooling condition during immersion. This can be caused by geometric features or equipment characteristics influencing local flow.

* ***Direction Along***: This is global coordinate that has the variation in the HTC. It should be perpendicular to the **Quench Direction**.
* ***Start Coordinate***: This is the X, Y, or Z coordinate, defined by the **Direction Along** parameter, that sets one side of the circumferential nonuniformity.
* ***Start Factor***: This is the scale factor that is applied to the **Ambient Quench HTC** definition, where one (1) equals the **Ambient Quench HTC** defined, and assigned to the **End Coordinate**..
* ***End Coordinate***: This is the X, Y, or Z coordinate, defined by the **Direction Along** parameter, that sets the other side of the circumferential nonuniformity.
* ***End Factor***: This is the scale factor that is applied to the **Ambient Quench HTC** definition, where one (1) equals the **Ambient Quench HTC** defined, and assigned to the **End Coordinate**. Customized Quenching ***DANTE\_thermal\_FILM-QUENCH.TXT*** File Format

### DANTE has the capability of customized quenching using film subroutine.

To use this capability, the ABAQUS ***FILM*** subroutine or Ansys ***USERCV*** subroutine is called by the model. The thermal boundary conditions in the input file are given below as an example:

* Abaqus/Standard solver: File name “***Model\_Name***” + ***“\_FILM-QUENCH.TXT***”, which should be located in the working directory.
* Ansys/Mechanical solver: File name "***DANTE\_thermal\_FILM-QUENCH.TXT***"

**The file is in keyword format, and an example is given below**. (There are 17 keywords)

**\*ITYPE\_QUENCH**

* The type of film quenching
* 1: Linear quench (Immersion quenching or spray quenching with linear transition)
* 2: Rotational quench (under development)

**\*NUM\_SURF\_TOT**

* The total number of surfaces defined (<=20 surfaces are allowed)

**\*START\_SURFACE**

* For each surface, a customized quenching information is defined inside **\*START\_SURFACE** and **\*END\_SURFACE**

**\*END\_SURFACE**

* For each surface, a customized quenching information is defined inside **\*START\_SURFACE** and \*\*\*END\_SURFACE

**\*SURFACE\_NAME**

* The name of the surface, the following command is required in the input file.

**\*TRANS\_COOL\_DIFF**

* The transverse cooling difference defined by coordinate direction, start coordinate, end coordinate, start HTC factor, end HTC factor (optional)

**\*QUENCH\_DIRECTION**

* The direction of movement of the part from point (0, 0, 0).

**\*TRAVEL\_SPEED**

* The speed of part traveling. The speed can be defined as a constant, or as a table (speed vs. time)

**\*QSTART\_TIME**

* At what time the immersion quench process starts for the defined surface name. (the default is 0.0s).
  * Example: If two surfaces A and B are defined to be quenched using the immersion user subroutines (\*Sfilm, FNU) with QSTART\_TIME=0.0 for surface A and QSTART\_TIEM=2.0 for surface B, then the immersion process for surface B will be delayed by 2.0 seconds relative to surface A. **\*QSTART\_LINE**
* The starting line of quench relative to the first point entering into the quench (default is 0.0mm). For a given part geometry (surface definition and meshing information) and an immersion orientation, the first point of the given surface entering into the quench tank liquid surface is calculated. By default, the point will be touching the quenchant at the time zero (with QSTART\_LINE being 0). If QSTART\_LINE=X (a positive number), then the part (surface) needs to travel X distance with the defined \*TRAVEL\_SPEED along the immersion orientation before the first point of the surface touching the quenchant.

<figure><img src="/files/8HHXVjKCH6VOMTUbLLhB" alt=""><figcaption></figcaption></figure>

**\*QEND\_LINE**

* The ending line of quench relative to the first point entering into the quench. Region between **\*START\_LINE** and **\*END\_LINE** is quenched. If **\*QEND\_LINE** < **\*QSTART\_LINE**, the quenching region is infinite below **\*QSTART\_LINE**.

**\*QEFFECT\_LINE** - The line to define residual effect from quenching (i.e. dribbling from spray quench). If **\*QEFFECT\_LINE** < **\*END\_LINE**, the region defined is infinite below **\*END\_LINE.**

**\*TAMBT\_AIR**

* The ambient temperature of air. It is defined as a constant.

**\*HTC\_AIR**

* The heat transfer coefficient of air. It is defined as a constant.

**\*TAMBT\_EFFECT**

* The ambient temperature of the after quench effect region. It is defined as a constant.

**\*HTC\_EFFECT**

* The heat transfer coefficient of the after quench effect region. It is defined as a constant.

**\*TAMBT\_QUENCH**

* The ambient temperature of the quenchant. It is defined as a function of time (version 6\_1 or later).
* The first column is Temperature value, and the second column is time.

**\*HTC\_QUENCH**

* The heat transfer coefficient of the quenching process. It is defined as a table (HTC vs. part surface temperature)

An example of the immersion property file is shown below.

```
** File Name: "Model Name" + "_FILM-QUENCH.TXT"
** 1: Linear Quench (Immersion or Spray)
** 2: Rotational Quench (Spray)
** 3: Gas Quench
**
*ITYPE_QUENCH
1
** The following format is for Linear Quench
** Number of Surfaces to define the HTC and ambient (<=20 allowed)
*NUM_SURF_TOT
1
**--Surface Name****************************************************
*START_SURFACE
**
*SURFACE_NAME
Exposed_Surfaces
**
**--Direction of immersion (0,0,0)-->(x1,y1,z1)---------------
*QUENCH_DIRECTION
0.0, -1.0, 0.0
** Travel speed in terms of time:  Speed (mm/s) <---> TIME(s)
*TRAVEL_SPEED
10.0
*QSTART_TIME
0.0
** *QSTART_LINE cannot be less than 0
*QSTART_LINE
0.0
** Negative *QEND_LINE number means infinity
*QEND_LINE
-1.0
*QEFFECT_LINE
0.0
**--Ambient temperature of Air--------------------------------
*TAMBT_AIR
20.0
**--Heat transfer coefficient of Air [W/(mm^2C)]--------------
*HTC_AIR
5e-05
**
**--Temperature of Effect Zone--------------------------------
*TAMBT_EFFECT
20.0
**--HTC of Effect Zone [W/(mm^2C)]--------------
*HTC_EFFECT
0.001
**
**--Temperature of quenchant [Unit: Degree C]---------
*TAMBT_QUENCH
65.0
**--HTC of quenchant--------------------
*HTC_QUENCH
0.0001,  20.0
0.0005,  150.0
0.0015,  300.0
0.002,  350.0
0.0025,  400.0
0.00375,  450.0
0.005,  500.0
0.005,  550.0
0.00475,  600.0
0.003,  650.0
0.002,  700.0
0.0015,  750.0
0.0013,  800.0
0.0005,  850.0
0.0008,  1000.0
*END_SURFACE
** Second Surface---------
**End of File
```


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