Modelling and numerical analysis of heat treatments on aluminium parts

A theoretical model suitable for the modelling and analysis of heat treatment problems is described. The presented formulations are implemented incrementally with a non-linear rate-dependent constitutive model, adequate to the simulation of a wide range temperature processes. The large deformation model is based on the additive decomposition of the strain rate tensor in elastic, thermal and viscoplastic parts. The flow rule is a function of the equivalent stress and the deviatoric stress tensor of the temperature field and of a set of internal state variables. The thermal problem is solved by a prediction/correction algorithm. The prediction, which uses a semi-implicit integration, provides a first estimation of the temperature field. The correction stage, performed with a Newton–Raphson implicit scheme, improves the solution until a satisfactory result is found. The thermomechanical coupled problem is solved with a staggered approach. The finite element formulations for coupled analysis of deformation and heat transfer given in this article are validated and applied to the process of quenching of aluminium parts into boiling water. Copyright q 2006 John Wiley & Sons, Ltd.