Creation method, creation device, creation system, program, and storage medium

Abstract

To provide a generation method, generation device, generation system, program, and storage medium, which can generate a more efficient heat treatment condition.SOLUTION: In a generation method, a master curve indicating a relationship between an extent of reaction and a heat treatment condition is generated using a thermal analysis result of a member. Also, in the generation method, first data related to a first heat treatment condition is generated using the master curve and the first heat treatment condition indicating a relationship between time and temperature. Further, in the generation method, a second heat treatment condition indicating a relationship between time and temperature is calculated using the master curve and a target condition for heat treatment.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a creating method, a creating device, a creating system, a program, and a storage medium. [Background technology]

[0002] In production, a heat treatment step using a thermal activation process may be carried out, and the heat treatment conditions in the heat treatment step are preferably more efficient. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-167663 A Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present invention is to provide a creating method, creating device, creating system, program, and storage medium that are capable of creating more efficient heat treatment conditions. [Means for solving the problem]

[0005] In the method according to the embodiment, a master curve showing the relationship between the reaction progress and the heat treatment conditions is created using the thermal analysis results of the component. The method further creates first data related to the first heat treatment conditions using the master curve and a first heat treatment condition showing the relationship between time and temperature. The method further calculates second heat treatment conditions showing the relationship between time and temperature using the master curve and target conditions for the heat treatment. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a flowchart showing a creation method according to an embodiment. [Diagram 2]FIG. 2 is a graph illustrating the thermal analysis results. [Diagram 3] FIG. 3 is a graph illustrating a master curve. [Figure 4] Fig. 4(a) is a graph illustrating the heat treatment conditions, and Fig. 4(b) is a graph illustrating the reaction behavior under the heat treatment conditions of Fig. 4(a). [Diagram 5] Fig. 5(a) is a graph showing an example of a reaction behavior created using the objective conditions and the constraint conditions, and Fig. 5(b) is a graph showing an example of heat treatment conditions corresponding to the reaction behavior of Fig. 5(a). [Figure 6] FIG. 6 is a schematic diagram showing a creation system according to an embodiment. [Figure 7] FIG. 7 is a schematic diagram showing a user interface of the creating device according to the embodiment. [Figure 8] FIG. 8 is a schematic diagram showing a user interface of the creating device according to the embodiment. [Figure 9] FIG. 9 is a schematic diagram showing a hardware configuration. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this specification and the drawings, elements similar to those already described are designated by the same reference numerals, and detailed description thereof will be omitted as appropriate.

[0008] FIG. 1 is a flowchart showing a creation method according to an embodiment. The preparation method according to the embodiment is used to prepare heat treatment conditions. As shown in FIG. 1, the preparation method M1 according to the embodiment includes steps S1 to S7. First, a thermal analysis is performed on the object of heat treatment (step S1). In the thermal analysis, the characteristics of the object with respect to temperature change are recorded. For example, the characteristics recorded include the thermogravimetric change rate, the thermal shrinkage rate, the elastic modulus, or the heat flow change. The thermogravimetric change rate can be measured by a thermogravimetric measuring device. The thermal shrinkage rate can be measured by a thermal shrinkage measuring device or a thermomechanical analyzer. The elastic modulus can be measured by a dynamic thermomechanical analyzer. The heat flow change can be measured by a differential scanning calorimeter. The thermal analysis is performed with two or more temperature profiles different from each other.

[0009] The temperature profile indicates the condition of temperature change with respect to time. For example, in thermal analysis, a plurality of temperature profiles with different heating rates are used. A plurality of temperature profiles with different cooling rates may also be used.

[0010] FIG. 2 is a graph illustrating the thermal analysis results. In FIG. 2, the horizontal axis indicates time t, and the vertical axis indicates the weight change rate w. Values ​​in arbitrary units are given to the horizontal and vertical axes. The graph shows the results of thermal analysis when a member is heated under three heating conditions with different heating rates. In the example of FIG. 2, the weight change rate with time differs for each heating condition. Also, the higher the heating rate, the greater the weight change rate with time.

[0011] A master curve is created using the thermal analysis results (step S2). The master curve is a function that indicates the relationship between the degree of reaction progress and the heat treatment conditions. In one embodiment, the master curve is expressed by the following formula 1. In formula 1, x is the degree of reaction progress. t is time. T is temperature. Q is activation energy. R is the gas constant. Θ(t,T) is a function with time t and temperature T as variables. Θ(t,T) is an integrated history from the start of heat treatment to an arbitrary time t and temperature T, and quantifies the heat treatment conditions.

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[0012] In Equation 1, m and n are variables that are set according to the phenomenon that occurs during heating. For example, phenomena that can occur during heating include chemical reactions, atomic diffusion, sintering, and drying. Chemical reactions include combination and decomposition. For example, atomic diffusion includes carburization, ion implantation, and sintering that bonds components at a temperature below the melting point. As another example, atomic diffusion is the diffusion of atoms from the surface to the inside of a solid in the formation of an alloy or compound. Examples of processes that cause diffusion from the surface to the inside of a solid include thermal oxidation and sulfurization. Drying includes volatilization and sublimation. When creating a master curve for chemical reactions or drying, m and n are set to "0". When creating a master curve for diffusion on the surface of a solid among atomic diffusion, m is set to "0" and n is set to "-1 / 2". When creating a master curve for sintering, m is set to "-1" and n is set to "0".

[0013] The master curve can be created using the known master sintering curve theory. In summary, first, the thermal analysis results are obtained under each heating condition, and the change in the property is plotted against Θ(t,T). In the example shown in FIG. 2, the property is the weight change rate. For plots with different temperature profiles, the value of Q that minimizes the distance between each plot is calculated. This results in a single curve showing the relationship between Θ(t,T) and the property. This curve is the master curve.

[0014] FIG. 3 is a graph illustrating a master curve. In FIG. 3, the horizontal axis indicates logΘ(t,T). The vertical axis indicates the weight change rate w. Values ​​in arbitrary units are given to the horizontal and vertical axes. The graph shows a part of the analysis results under three heating conditions with different heating rates, and the average of all the analysis results. It can be seen from FIG. 3 that the changes in characteristics under different heating conditions converge to a single curve.

[0015] A master curve is applied to the existing heat treatment conditions (first heat treatment conditions) to calculate the reaction progress under the first heat treatment conditions (step S3). As described above, the master curve indicates the relationship between the reaction progress and the heat treatment conditions. The heat treatment conditions define the change in temperature T with respect to time t. By using the master curve, the heat treatment conditions can be converted into the reaction progress. The reaction progress indicates the degree of reaction progress with respect to time and temperature. Furthermore, from the converted reaction progress, reaction behavior indicating the change in reaction progress with respect to time can be obtained.

[0016] Fig. 4(a) is a graph illustrating the heat treatment conditions, and Fig. 4(b) is a graph illustrating the reaction behavior under the heat treatment conditions of Fig. 4(a). In Fig. 4(a), the horizontal axis represents time t, and the vertical axis represents temperature T. In Fig. 4(b), the horizontal axis represents time t, and the vertical axis represents reaction rate v. The reaction rate v can be calculated from the reaction progress, and represents the change in reaction progress over time. The horizontal and vertical axes are given values ​​in arbitrary units.

[0017] By applying the master curve to the heat treatment conditions shown in Figure 4(a), the reaction behavior (first reaction behavior) shown in Figure 4(b) is obtained. In the example shown in Figure 4(b), two peaks of the reaction rate v appear, and two reactions occur. When multiple reactions occur, a master curve is created for each reaction, and the heat treatment conditions are converted into reaction behavior using the multiple master curves.

[0018] First data is obtained from the reaction behavior (step S4). For example, the first data is a score indicating an evaluation of the first reaction behavior. The score S can be calculated using the following formulas 2 and 3. In formulas 2 and 3, n is the number of reactions that occur under the heat treatment conditions. S i is the score for the i-th response. t i is the processing time for the i-th reaction. t ideal is the treatment time under ideal conditions for the i-th reaction. A i is the area of ​​the i-th reaction in the graph, i.e., A iis the integral of the reaction rate v with respect to time t for the i-th reaction. V i is the maximum value of the reaction rate v for the i-th reaction.

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[0019] For example, the more efficiently the reaction occurs, the higher the score. The user can understand from the score how efficiently the reaction occurs under the first heat treatment condition. i , V i , A i Values ​​such as may be calculated from the first reaction behavior. These values ​​can be used when the user sets constraint conditions or target conditions, which will be described later. Alternatively, the first data may be the reaction behavior itself obtained from existing heat treatment conditions. From the reaction behavior, the reaction progress can be confirmed for each time, and it is possible to understand how efficiently the reaction is proceeding at each time. The first data includes a score and t i , V i , A i One or more selected from the above and reaction behavior may be obtained.

[0020] Target conditions for the heat treatment are set (step S5). The target conditions indicate the purpose for generating the reaction behavior, and the parameters to be minimized, maximized, or brought closer to a desired value are specified by the target conditions. As the target conditions, conditions related to the progress of the reaction, conditions related to time, etc. are set. For example, as target conditions related to the progress of the reaction, the leveling of the reaction rate, the separation of two or more reactions, etc. are set. For the leveling, a reference reaction rate is set. The reaction rate is leveled so that the difference from the reference reaction rate is minimized. As a condition related to time, the minimization of the processing time, etc. is set. Two or more target conditions may be set.

[0021] Constraint conditions may be further set for the heat treatment. The constraint conditions indicate the constraints when generating the reaction behavior, and the conditions that the parameters must satisfy are specified by the constraint conditions. As the constraint conditions, conditions regarding the progress of the reaction, conditions regarding temperature, conditions regarding time, etc. are set. For example, as the constraint conditions regarding the progress of the reaction, an upper limit on the reaction rate is set. As the constraint conditions regarding temperature, a maximum temperature, a temperature rise rate, etc. are set. As the constraint conditions regarding time, an upper limit on the processing time, etc. may be set. Two or more constraint conditions may be set.

[0022] When setting the objective condition or the constraint condition, the user may refer to the first data obtained from the first reaction behavior. As an example, the first data includes a maximum value of the reaction rate. The user sets a reference value for leveling the reaction rate with reference to the maximum value of the reaction rate.

[0023] Using the set target conditions, a reaction behavior (second reaction behavior) that conforms to the target conditions is created (step S6). If constraint conditions are set, a second reaction behavior that satisfies the constraint conditions is created. If a reaction behavior that satisfies the constraint conditions cannot be created, another target condition or another constraint condition is input again. By applying a master curve to the second reaction behavior, the second reaction behavior is converted into a corresponding heat treatment condition (second heat treatment condition) (step S7).

[0024] Fig. 5(a) is a graph showing an example of a reaction behavior created using the objective conditions and the constraint conditions, and Fig. 5(b) is a graph showing an example of heat treatment conditions corresponding to the reaction behavior of Fig. 5(a). FIG. 5(a) is an example of the created reaction behavior. FIG. 5(b) is an example of the heat treatment conditions obtained by applying a master curve to the reaction behavior shown in FIG. 5(a). In FIG. 5(a), the horizontal axis indicates time t, and the vertical axis indicates the reaction rate v. In FIG. 5(b), the horizontal axis indicates time t, and the vertical axis indicates the temperature T. The horizontal and vertical axes are given values ​​in arbitrary units. In FIG. 5(a), the reaction behavior shown in FIG. 4(b) is shown by a dashed line. In FIG. 5(b), the heat treatment conditions shown in FIG. 4(a) are shown by a dashed line.

[0025] From Fig. 5(b), it can be seen that under the newly created second heat treatment conditions, the total treatment time is shortened by time t1 compared to the existing first heat treatment conditions. Also, from Fig. 5(a), it can be seen that under the second heat treatment conditions, the maximum reaction rate is reduced by a value v1 compared to the first heat treatment conditions. A reduction in treatment time indicates improved reaction efficiency, leading to improved productivity. A reduction in the maximum reaction rate leads to a reduction in the load on the product, or a reduction in the load on the associated equipment that processes the exhaust gas generated during heat treatment.

[0026] Advantages of the embodiment will be described. In production, a heat treatment process using a thermal activation process may be carried out. The thermal activation process may be a chemical reaction, an atomic diffusion, a sintering, a drying, etc. Conventionally, the relationship between time and temperature in a heat treatment process has been set based on experience, the results of repeated experiments, etc. With conventional methods, even if there is waste in the heat treatment conditions, it is not easy to find the waste. In addition, when the heat treatment conditions are changed, it is difficult to predict the effect on the reaction behavior, making it difficult to optimize the heat treatment conditions.

[0027] Regarding this problem, in the embodiment, a master curve is used to create heat treatment conditions. The master curve shows the relationship between the reaction progress and the heat treatment conditions. By creating the master curve, it is possible to grasp how the reaction is progressing in the target member. Using the created master curve and the target conditions for the heat treatment, more efficient heat treatment conditions can be created. In addition, by applying the master curve to existing heat treatment conditions, it is possible to specify waste related to the existing heat treatment conditions, or to obtain data that is useful when creating new heat treatment conditions. According to the embodiment, it is possible to obtain data related to the existing heat treatment conditions and create more efficient heat treatment conditions.

[0028] The master curve uses Equation 1. According to Equation 1, by setting parameters according to the phenomenon, it is possible to deal with four phenomena, namely, chemical reaction, atomic diffusion, sintering, and drying. Therefore, the method according to the embodiment can deal with a wider range of thermal activation processes.

[0029] Furthermore, in the method according to the embodiment, even if multiple reactions occur in the target component during heat treatment, appropriate heat treatment conditions can be created by calculating the activation energy for each reaction and creating a master curve.

[0030] In the above-mentioned creation method, the master curve is applied to the first heat treatment conditions in order to obtain data that can be used for evaluation of the existing first heat treatment conditions and for setting target conditions or constraint conditions, etc. When evaluation or usable data is not required, application of the first heat treatment conditions to the master curve can be omitted.

[0031] The methods according to the embodiments may be performed by a human, or at least a part of the methods may be performed by an apparatus.

[0032] FIG. 6 is a schematic diagram showing a creation system according to an embodiment. The creation system 10 is used to create heat treatment conditions, and includes a creation device 1, an analysis device 2, a storage device 3, an input device 4, and an output device 5, as shown in FIG.

[0033] The creation device 1 executes various processes related to the creation of heat treatment conditions. The analysis device 2 executes thermal analysis of the target component. The storage device 3 appropriately stores data used to create the heat treatment conditions and data obtained by the processing of the creation device 1. The input device 4 is used by a user to input data to the creation device 1. The output device 5 outputs data transmitted from the creation device 1 to the outside.

[0034] First, the analysis device 2 executes a thermal analysis. The analysis device 2 may execute the thermal analysis automatically according to a command sent from the creation device 1. The conditions for executing the thermal analysis are set in advance by a user. The creation device 1 acquires the thermal analysis results by the analysis device 2. For example, the creation device 1 receives the thermal analysis results from the analysis device 2. The thermal analysis results may be stored in a storage medium, and the creation device 1 may acquire the thermal analysis results from the storage medium. The thermal analysis results may be transferred from the analysis device 2 to the creation device 1 by a user.

[0035] The creation device 1 creates a master curve using the thermal analysis results. The creation device 1 also accepts input of existing first heat treatment conditions. The first heat treatment conditions may be input using the input device 4, or may be stored in the storage device 3. The creation device 1 creates first data using the first heat treatment conditions and the master curve, and causes the output device 5 to output the first data.

[0036] A user inputs target conditions or constraint conditions using the input device 4. Alternatively, the creation device 1 may automatically set target conditions or constraint conditions based on the first data in accordance with a preset rule. The creation device 1 creates a reaction behavior using a master curve, target conditions, and constraint conditions. The creation device 1 converts the reaction behavior into heat treatment conditions using the master curve. The creation device 1 outputs the converted heat treatment conditions to the output device 5 and stores them in the storage device 3.

[0037] 7 and 8 are schematic diagrams showing a user interface of the creating device according to the embodiment. For example, the output device 5 is a monitor. As shown in FIG. 7, the creation device 1 displays a user interface (UI) 100. For the purpose of improving user convenience, it is preferable that the creation device 1 displays the existing conditions, the score of the first heat treatment conditions, and the new conditions on the UI 100. The existing conditions are one or two selected from the existing first heat treatment conditions and the first reaction behavior corresponding to the first heat treatment conditions. The new conditions are one or two selected from the newly created second reaction behavior and the second heat treatment conditions corresponding to the second reaction behavior. For example, the creation device 1 displays the existing conditions, the score, and the new conditions on the UI 100 in response to input of the thermal analysis results, the first heat treatment conditions, and the target conditions.

[0038] 7, the UI 100 displays a first heat treatment condition 101, a first reaction behavior 102, a second heat treatment condition 103, a second reaction behavior 104, a score 105 of the first heat treatment condition, and a score 106 of the second heat treatment condition. These displays allow the user to easily understand how efficient the first heat treatment condition is, how efficient the second heat treatment condition is compared to the first heat treatment condition, and so on.

[0039] The objective conditions and constraint conditions may be input by drawing a reaction behavior on the UI. For example, as shown in FIG. 8, the creation device 1 displays a drawing area 110 on the UI 100. The user uses the input device 4 to operate a pointer 111 and draws a reaction behavior on the drawing area 110. The creation device 1 accepts the drawn reaction behavior. The creation device 1 calculates the objective conditions and constraint conditions from the input reaction behavior. For example, the creation device 1 calculates a processing time and a maximum reaction speed from the input reaction behavior, and sets the objective conditions and constraint conditions based on these values.

[0040] When drawing a reaction behavior, it is preferable that existing conditions are displayed as shown in Fig. 7. This allows even a user with little experience or knowledge to easily draw the reaction behavior by referring to the existing conditions.

[0041] If the phenomenon occurring in the heat treatment is known, the parameters m and n in Equation 1 can be set when creating the master curve. If the phenomenon occurring is unknown, the creation device 1 may automatically set the parameters m and n that best fit the thermal analysis results. For example, the creation device 1 substitutes the values ​​of the three combinations described above for the parameters m and n. The creation device 1 determines the combination of values ​​that can best represent the thermal analysis results, and creates the master curve using that combination of values.

[0042] FIG. 9 is a schematic diagram showing a hardware configuration. The creation device 1 includes, for example, the configuration of a computer 90 shown in Fig. 9. The computer 90 includes a CPU 91, a ROM 92, a RAM 93, a storage device 94, an input interface 95, an output interface 96, and a communication interface 97.

[0043] The ROM 92 stores a program for controlling the operation of the computer 90. The ROM 92 stores a program necessary for causing the computer 90 to realize each of the above-mentioned processes. The RAM 93 functions as a storage area in which the programs stored in the ROM 92 are expanded.

[0044] The CPU 91 includes a processing circuit. The CPU 91 uses a RAM 93 as a working memory and executes a program stored in at least one of a ROM 92 and a storage device 94. During execution of the program, the CPU 91 controls each component via a system bus 98 and executes various processes.

[0045] The storage device 94 stores data necessary for executing the programs and data obtained by executing the programs.

[0046] The input interface (I / F) 95 connects the computer 90 and the input device 95a. The input I / F 95 is, for example, a serial bus interface such as USB. The CPU 91 can read various data from the input device 95a via the input I / F 95.

[0047] The output interface (I / F) 96 connects the computer 90 and the output device 96a. The output I / F 96 is, for example, a video output interface such as a Digital Visual Interface (DVI) or a High-Definition Multimedia Interface (HDMI (registered trademark)). The CPU 91 transmits data to the output device 96a via the output I / F 96 and can cause the output device 96a to display an image.

[0048] The communication interface (I / F) 97 connects the computer 90 to a server 97a external to the computer 90. The communication I / F 97 is, for example, a network card such as a LAN card. The CPU 91 can read various data from the server 97a via the communication I / F 97.

[0049] The storage device 94 includes one or more selected from a hard disk drive (HDD) and a solid state drive (SSD). The input device 95a includes one or more selected from a mouse, a keyboard, a microphone (audio input), and a touchpad. The output device 96a includes one or more selected from a monitor and a projector. A device having the functions of both the input device 95a and the output device 96a, such as a touch panel, may be used. The storage device 94, the input device 95a, and the output device 96a can be used as the storage device 3, the input device 4, and the output device 5, respectively.

[0050] The functions of the creation device 1 may be realized by the cooperation of multiple computers. The above-mentioned various data processing may be recorded as a program that can be executed by a computer on a magnetic disk (such as a flexible disk or a hard disk), an optical disk (such as a CD-ROM, a CD-R, a CD-RW, a DVD-ROM, a DVD±R, or a DVD±RW), a semiconductor memory, or other non-transitory computer-readable storage medium.

[0051] For example, information recorded on a recording medium can be read by a computer (or an embedded system). The recording medium may have any recording format (storage format). For example, the computer reads a program from the recording medium and causes a CPU to execute instructions described in the program based on the program. The computer may acquire (or read) the program via a network.

[0052] According to the above-described manufacturing method, manufacturing device, and manufacturing system, it is possible to create more efficient heat treatment conditions. The same effect can be obtained by using a program that causes a computer to execute the manufacturing method.

[0053] Although some embodiments of the present invention have been illustrated above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, modifications, etc. can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are included in the scope of the invention and its equivalents described in the claims. In addition, the above-mentioned embodiments can be implemented in combination with each other. [Explanation of symbols]

[0054] 1: Creation device, 2: Analysis device, 3: Storage device, 4: Input device, 5: Output device, 10: Creation system, 90: Computer, 101: First heat treatment condition, 102: First reaction behavior, 103: Second heat treatment condition, 104: Second reaction behavior, 105, 106: Score, 110: Drawing area, 111: Pointer, M1: Creation method

Claims

1. A method for obtaining a thermal analysis result showing a change in the properties of a component relative to a temperature change by performing a thermal analysis using a plurality of temperature profiles having mutually different heating or cooling rates; Using the thermal analysis results, a master curve showing the relationship between the reaction progress and the heat treatment conditions is created; By applying the master curve to a first heat treatment condition that indicates a relationship between time and temperature, a first reaction behavior that indicates a change in reaction progress with respect to time is created; creating first data from the first reaction behavior, the first data including one or more selected from a score indicating an evaluation of the first reaction behavior, a processing time for a reaction appearing in the first reaction behavior, a maximum value of a rate of the reaction, and an integral value of the rate of the reaction with respect to time; creating a second reaction behavior according to the target conditions using the first reaction behavior and the target conditions for the heat treatment; A method for creating heat treatment conditions, comprising applying the master curve to the second reaction behavior to calculate second heat treatment conditions that indicate a relationship between time and temperature corresponding to the second reaction behavior.

2. The method for creating heat treatment conditions according to claim 1 , further comprising the step of calculating the second heat treatment conditions using a constraint condition for the heat treatment.

3. the master curve includes parameters corresponding to at least any of a plurality of phenomena that may occur during heat treatment; 3. The method for creating heat treatment conditions according to claim 1 or 2, wherein, when one of the phenomena is selected, a value corresponding to the one selected phenomenon is set to the parameter to create the second heat treatment condition.

4. When multiple reactions occur during the heat treatment, the master curve is created for each of the multiple reactions; 4. The method for creating heat treatment conditions according to claim 1, further comprising the step of creating the second heat treatment conditions using a plurality of the master curves and the target conditions.

5. A creating device that executes the method for creating heat treatment conditions according to any one of claims 1 to 4.

6. The creation device according to claim 5 ; An output device; Equipped with A creation system in which the creation device displays at least one of the first heat treatment conditions, the first reaction behavior, the second heat treatment conditions, the second reaction behavior, and the first data on the output device.

7. A program for causing a computer to execute the method for creating heat treatment conditions according to any one of claims 1 to 4.

8. A storage medium storing a program for causing a computer to execute the method for creating heat treatment conditions according to any one of claims 1 to 4.

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