Heat treated steel components often suffer distortion and residual stress effects when cooled to room temperature. A numerical analysis of a vacuum gas quenched die block made of H 13 was carried out utilising a nonlinear thermoelastic-plastic stress model together with the fluid flow and thermal profiles within the furnace. Simulation procedures for stress behaviour of the die were developed for both direct quench and marquench processes. Results of the initial thermal analysis indicated that the temperature difference between the surface and core of the die during direct quenching (gas pressure is 4 bar) was larger than that due to marquenching ( gas pressure is 4 bar at the beginning and 2 bar near isothermal hold). Simulation of the cooling rates at the surface and core of the die during marquenching correlated well with the experimental data. Further stress simulation indicated that the final thermal distortion and residual stresses in the die after direct quenching were larger than those due to marquenching. The findings of the numerical analysis suggested that marquenching is recommended for this die because it could reduce the temperature difference in the die and thus result in less thermal distortion and residual stresses.
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