Super Systems CarbCALC II User Manual

Download

CarbCalc II

Carbon Diffusion Model for

Atmosphere Furnaces

Super Systems Inc

7205 Edington Drive

Cincinnati,OH 45249

CarbCalc III

Table of Contents

Part I

Part II

Introduction

................................................................................................................................... 31 Welcome to SuperSystems

................................................................................................................................... 42 CarbCalcII Introduction

CarbCalcII

................................................................................................................................... 71 Overview

................................................................................................................................... 82 Typical Uses

................................................................................................................................... 93 Menu and Toolbar

................................................................................................................................... 104 Displays

.......................................................................................................................................................... 10Atmosphere Display Area

.......................................................................................................................................................... 11Model Segment Display Area

.......................................................................................................................................................... 12Segment Properties Dialog

.......................................................................................................................................................... 13Temperature and Carbon Chart

.......................................................................................................................................................... 14Carbon Profile Chart

................................................................................................................................... 155 Users and Security

.......................................................................................................................................................... 15Login

.......................................................................................................................................................... 16Manage Users

................................................................................................................................... 176 Parts and Loads

.......................................................................................................................................................... 17Loads

.......................................................................................................................................................... 17Control Mode

.......................................................................................................................................................... 20Monitor Mode

.......................................................................................................................................................... 21BatchMaster Mode

................................................................................................................................... 237 Model and Furnace Settings

.......................................................................................................................................................... 23Settings Overview

.......................................................................................................................................................... 23Model Settings

.......................................................................................................................................................... 24Furnace Settings

.......................................................................................................................................................... 26Furnace RealTime Setup

................................................................................................................................... 288 Material Selection

.......................................................................................................................................................... 28Material Dtabase

.......................................................................................................................................................... 29Initial Carbon Profile

................................................................................................................................... 319 Target Profile

.......................................................................................................................................................... 31Specifying a Target Profile

.......................................................................................................................................................... 32Recommended Profile

................................................................................................................................... 3310 Carbobn Profiles

.......................................................................................................................................................... 33Carbobn Profile Dialog

................................................................................................................................... 3611 SuperCalc

.......................................................................................................................................................... 36The SuperCalc Application

................................................................................................................................... 3712 Simulation Mode

.......................................................................................................................................................... 37Typical Uses

......................................................................................................................................................... 18Entering a Load

......................................................................................................................................................... 19Load History in Control Mode

......................................................................................................................................................... 19Parts in Control Mode

.......................................................................................................................................................... 37Report

................................................................................................................................... 3913 RealTime Control Mode

.......................................................................................................................................................... 39Typical Uses

.......................................................................................................................................................... 39Report

................................................................................................................................... 4114 Replay Monitor Mode

.......................................................................................................................................................... 41Typical Uses

.......................................................................................................................................................... 43Report

IIContents

Part III

CarbCalcII Configuration

Index 0

1 Introduction

1.1 Welcome to SuperSystems

Super Systems Inc.

Super Systems Introduces

Load Tracking and RealTime Control

No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without prior written permission of Super Systems Inc., 7205 Edington Dr., Cincinnati, OH 45249 USA.

CARBCALCII is a software program to be used by the Heat Treater. Super Systems Inc. is not responsible or liable for any product, process, or damage or injury incurred as a result of using CARBCALCII. Super Systems Inc. makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties or merchantability or fitness for any particular purpose.

IntroductionCarbCalc II3

CarbCalcII

with

DISCLAIMER

1.2 CarbCalcII Introduction

CarbCalcII is a Carbon Diffusion Model for use with Batch Furnace Gas Carburizing.

IntroductionCarbCalc II 4

Gas Carburizing

low-carbon steel part at a temperature sufficient to render the steel austenitic, followed by quenching and tempering to form a martensitic microstructure. The resulting gradient in carbon content below the surface of the part causes a gradient in hardness, producing a strong, wear-resistant surface layer on a material, usually low-carbon steel, which is readily fabricated into parts. In gas carburizing the source of carbon is a carbon-rich furnace atmosphere produced either from gaseous hydrocarbons, for example, methane (CH4), propane (C3H3), and butane (C4H10), or from vaporized hydrocarbon liquids.

Carbon Sources

Low-carbon steel parts exposed to carbon-rich atmospheres will carburize at temperatures of 850°C (1560°F) and above. If the carbon source is so rich that the solubility limit of carbon in austenite is reached at the surface of the steel some carbides may form at the surface. At these "above saturation" atmospheres soot will deposit on surfaces within the furnace, including the parts. The goal of modern gas carburizing practice is to control the carbon content of furnace atmospheres such that: The final carbon concentration at the surface of the parts is below the solubility limit in austenite and Sooting of the furnace atmosphere is minimized. Endothermic gas (Endogas) is a blend of carbon monoxide, hydrogen, and nitrogen (with smaller amounts of carbon dioxide water vapor, and methane) produced by reacting a hydrocarbon gas such as natural, gas (primarily methane), propane or butane with air. A

is a case-hardening process in which carbon is dissolved in the surface layers of a

IntroductionCarbCalc II5

carrier gas similar in composition to Endogas may be produced from methane can be formed from a nitrogen-methanol blend.

Carburizing Process Variables

The gas carburizing process depends on the control of three principal variables:

Temperature

Time

Atmosphere composition. Other variables that affect the amount of carbon transferred to parts include the degree of atmosphere circulation and the alloy content of the parts.

Temperature

. The maximum rate at which carbon can be added to steel is limited by the rate of diffusion of carbon in austenite. This diffusion rate increases greatly with increasing temperature; the rate of carbon addition at 925°C (1700°F) is about 40% greater than at 870°C (1600°F). The temperature most commonly used for carburizing is 925°C (1700°F). This temperature permits a reasonably rapid carburizing rate without excessively rapid deterioration of furnace equipment. The carburizing temperature is sometimes raised to 955°C (1750°F) or 980°C (1800°F) to shorten the time of carburizing for parts requiring deep cases. Conversely, shallow case carburizing is frequently done at lower temperatures because case depth can be controlled more accurately with the slower rate of carburizing obtained at lower temperatures. For best results, the workload should be heated to the carburizing temperature in a near-neutral furnace atmosphere. In batch furnaces, parts can be heated in Endogas until they reach the furnace temperature; then carburizing can commence with the addition of the enriching gas.

Time.

The effect of time and temperature on the Carbon vs Depth profile shows that the carburizing time decreases with increasing carburizing temperature. In addition to the time at the carburizing temperature, several hours may be required to bring large work pieces or heavy loads of smaller parts to operating temperature. For a work piece quenched directly from the carburizing furnace, the cycle may be lengthened further by allowing time for the work piece to cool from the carburizing temperature to about 843°C (1550°F) prior to quenching. Similarly, additional diffusion and interchange of carbon with the atmosphere will occur during cooling prior to quenching.

Carbon Potential.

The carbon potential of the furnace atmosphere must be greater than the carbon potential at the surface of the work piece in order for carburizing to occur. It is the difference in carbon potential that provides the driving force for carbon transfer into the parts.

Carbon Diffusion.

The combined effects of time, temperature, and carbon concentration on the

diffusion of carbon in austenite can be expressed by Fick's laws of diffusion.

Alloy Effects.

The various alloying elements found in carburizing steels have an influence on the

activity of carbon dissolved in austenite.

Chromium

Nickel

tends to decrease the activity of carbon

tends to raise the activity of carbon The primary effect of alloys on the diffusion of carbon is their effect on the driving force at the surface reaction.

The CarbCalcII Model

CARBCALCII is a carbon difussion model for simulation and analysis of gas carburizing process for low-alloy steels. The interactions of the gas carburizing process cannot be modeled by simple one-dimensional analysis. In order to accurately predict how a low-alloy steel will react in a controlled atmosphere process, many factors must be taken into account, including:

Alloy steel composition

Equilibrium and non-equilibrium gas composition

Temperature

Atmosphere agitation

Surface radius of curvature, concave or convex

IntroductionCarbCalc II 6

Initial carbon profile CARBCALCII takes as many factors as possible into account for the accurate prediction of (1) transfer of carbon between gas and steel surface, and (2) diffusion of carbon within the steel.

Possible uses for CARBCALCII include:

Computer-aided design of heat treatment processes

Optimization of existing cycles

"What if" analysis when a change in an existing process or material is contemplated

Reconstruction of the effects that an out-of-control process may have had on a load

Education of personnel in the intricacies of atmosphere processing

Real-Time control with an on-line process CARBCALCII can pay for itself quickly because process development experiments can be carried out

quickly on the computer instead of weeks in a furnace. When a trial is finally made in the furnace, the results will be reasonably close to those predicted by the software.

CARBCALCII has thee main operating modes:

1. Simulation

2. RealTime Control

3. Monitor/Replay The object in all cases is to accurately predict the diffusion gradient that carbon establishes in a given material from a given set of processing parameters.

SIMULATION

allows construction of a diffusion gradient from complex a set of processing parameters. For example, in a batch integral quench furnace, one might be interested in the following sequence:

Come to Heat

Boost Carburize

Diffuse Carburize

Equalize for Quench

Brief Exposure to Vestibule Atmosphere

REALTIME CONTROL

- CarbCalcII is able to connect to "dumb controllers" via SuperData communications. In this mode, CarbCalcII becomes the "Recipe Programmer" and sends setpoints to the Temperature and Carbon Controllers.

MONITOR/REPLAY

running and logged in SuperData. This mode can be integrated with BatchMaster furnace control systems.

is used to view the Carbon Profile for load cycles previously run or currently

2 CarbCalcII

2.1 Overview

CarbCalcIICarbCalc II7

The Main Screen.

Menu and ToolBar:

Furnace Atmosphere Display:

material information and timers.

Recipe Segment Display:

Recipe Temperature and Carbon Chart:

displays segment markers.

Carbon Profile Chart:

Saturation Carbon line.

Provides access to Files, Printer and Model settings.

Displays Temperature, %Carbon and Gas values. Also displays

Displays the Recipe segments in the current model, (Max 8 segments).

Displays Initial Carbon, Carbon Diffusion profile, Target profile and

Displays theTemperature and Carbon vs Time. Also

2.2 Typical Uses

Simulation mode

Up to 8 segments may be modeled.

For each segment, define the Segment Name, Temperature, Carbon and End-Of-Segment (EOS) type.

EOS types are:

1. Timed - ends after a specified time.

2. Match Surface Carbon - ends when Surface Carbon matches the Target Surface Carbon.

3. Match Carbon at a specified depth - ends when Diffused Carbon matches Carbon at a specified depth.

4. Auto Boost - ends when the amount of excess carbon near the surface exceeds the deficient carbon at depth.

5. Auto Diffuse - ends when the deviation between the diffused profile and the target profile is minimized (curve matching).

Model Temperature units may be displayed in Celsius of Fahrenheit and Measurement units in inches or mm.

Probe Factors may use either the CO Factor or the Process Factor (typical to Marathon Instruments) .

The Type of Material may be selected from a Material Database.

The Initial Carbon Profile is based on the material selected and is assumed to be uniform.

The Initial Carbon Profile may be customized based on 10 points - useful for modeling "Rework" recipes.

The Target Profile (up to 10 points) may be specified or you can request a recommended profile based on Surface Carbon, Carbon at Effective Case Depth and Carbon at total Case Depth.

After starting the simulation, it may be paused at any time. You can also set it to "AutoPause" at the end of each segment.

CarbCalcIICarbCalc II 8

, CabcalcII is used to develop Batch Carburizing Segment recipes.

RealTime Control mode

In Controller and is used to Control a running Batch Furnace Carb Cycle.

A simple Load Entry system is used

The Segment display represents the Carb Cycle Recipe.

The Time vs Temperature and Carbon chart displays both the Setpoints and Actual values for Temperature and Carbon.

The Carbon Profile is based on actual data from the instruments.

Instrument communication data sources are easily configured from within the application and saved in a "Furnace" file.

Monitor/Replay mode

In data logged by the SuperSystems communications datalogger. This mode is useful in analyzing a comparing a cycle profile with the actual Profile from Lab results.· Display is similar to RealTime mode but the data source is from the historical logged data.

Model runs at high speed similar to simulation mode.

Model may be paused, stopped or restarted at any time.

Target profile may be used to compare actual Lab measured profile for comparison with the model results.

Analysis may be helpful in "Tuning" the recipe to achieve more precise results.

, CarbCalcII is connected to a Carbon Controller and a Temperature

, CarbCalcII is used to reproduce a cycle based on a Furnace Load and the

2.3 Menu and Toolbar

Menu Items

File

ToolBar Items

- Provides standard file open, save and close routines for CarbCalcII Model Files.

Help

- Opens Help file and About box.

CarbCalcIICarbCalc II9

New Model - Opens the default New Model

Save Model - saves the current model.· Print - prints the Carbon Profile report.

Model and Furnace Settings - Opens the

Model and Furnace settings dialog.

Carbon Profiles - Opens the Carbon Profiles

dialog.

Help - Opens this help file.

Open Model - displays the File Open

dialog for CarbCalcII Model Files

(report depends on model mode and settings see Reports in this help file)

Material - Opens the Material selection

dialog.

SuperCalc - Opens the SuperCalc

program.

2.4 Displays

2.4.1 Atmosphere Display Area

CarbCalcIICarbCalc II 10

Atmosphere

All atmosphere values are displayed. Model Inputs (yellow background) are "given" or "assumed" values. Monitored values (green background) are used only in the RealTime and Replay modes. Calculated values (blue background) are calculated based on Model Inputs and the assumption that the atmosphere is in equilibrium. In simulation mode, the inputs will always be Temperature, %Carbon, Probe Factor and CH4. In Realtime and Replay modes the model inputs are selectable. In these modes, data that is available but not selected as a model input may be monitored - in this case, a monitored value will be displayed next to the model value.

Temperature

%Carbon

PF or COF

O2mV

dependent on Temperature. When designing recipes, a good rule of thumb is to keep the %C setpoint below about 90% of the Saturation Carbon.

- Oxygen Probe millivolts

%CO

- %Carbon Monoxide in the furnace atmosphere

%H2

- %Hydrogen Monoxide in the furnace atmosphere

%CO2

- %Carbon Dioxide in the furnace atmosphere

%H2O

- %Water in the furnace atmosphere

%CH4 %C/CH4

Saturation Carbon

- units may be in Fahrenheit or Celsius.

- Carbon Potential (based on water-gas equations)

- Process Factor or CO Factor (depends on type of controller)

- %Hydrocarbon in the furnace atmosphere

- Efective%Carbon with CH4 taken into consideration

- the level at witch free carbon (soot) precipitates in the atmosphere. Primarily

Dewpoint

Material

material toolbar icon.

Timers

Model Run Controls

- displays the calculated Dewpoint for the given atmosphere.

- displays the material selected, may be changed by opening the material dialog with the

-Displays the Total elapsed time and segment elapsed time in minutes.

- Used to start, stop, pause and reset the simulation.

2.4.2 Model Segment Display Area

CarbCalcIICarbCalc II11

Model Recipe

Segment

paused or stopped, you may click on the segment name to open the segment properties dialog and edit the segment.

Temp

- The temperature for the segment. You may edit the temperature for segments that have not

yet executed.

%Carb

executed.

EOS Type

available:

RunTime Pause Checkbox

end of each segment.

Total Timer

Note:

It is not normally not displayed during Monitor and Replay modes.

- The %Carbon for the segment. You may edit the %Carbon for segments that have not yet

Timed Soak

Timed Ramp

Surface

Depth

AutoBoost

5. "Excess" carbon is the carbon above the "target" profile and "deficient" carbon is carbon below the target profile.

AutoDiffuse

The Model Segment Display Area is always used in Simulation and Realtime Control Modes.

may have up to 8 Segments.

- the name given to the segment (defaults to Seg1, Seg2, etc). When the simulation is

- The End-Of-Segment type determines how the segment terminates. There are 6 types

- ends after a given time is reached.

- ramps temperature ends after a given time is reached.

- ends when the Carbon profile "matches" a specified Surface Carbon.

- ends when the Carbon profile "matches" a specified carbon at a specified depth.

- ends when the "excess" carbon is sufficient to satisfy the "deficient" carbon.

- ends when the Carbon Profile matches the Target Profile ("best fit") .

- displays the segment time in days, hours and minutes (D:HH:MM).

- (simulation and replay only) check this box to make the simulation pause at the

- displays the total time in days, hours and minutes (D:HH:MM).

2.4.3 Segment Properties Dialog

CarbCalcIICarbCalc II 12

Segment Name

Temperature

%Carbon

Probe Factor

to the Suggested PF and may be edited.

Residual CH4

Saturation Carbon

this amount.

Suggested Probe Factor

selected.

End of Segment Method

below.

- Enter or Edit the Segment Name.

- Enter or Edit the Segment Temperature

- Enter or Edit the Segment %Carbon. (PF or COF) - Enter or Edit the Probe Factor. Note: for new segments this will default

- Enter or Edit the CH4 (normally 0.0 to 5.0 depending on your furnace).

- displays saturation carbon level, %Carbon should be set to a value less than (PF or COF) - Theoretical value of the Probe Factor based on Material

- select the End of Segment type and supply required data as indicated

CarbCalcIICarbCalc II13

Delete Button

Insert Button

OK Button

- clicking on this button will delete this segment from the model.

- clicking this button inserts the segment as a new segment.

- exits the dialog and saves changes to the segment.

2.4.4 Temperature and Carbon Chart

Simulation mode

In executed.

RealTime

In process variables and setpoints are displayed and times are displayed as actual clock times rather than elapsed times.

and

, the Temperature and Carbon Chart displays a profile of the recipe as it is

Replay modes

2.4.5 Carbon Profile Chart

CarbCalcIICarbCalc II 14

, the Actual monitored values of the Temperature and Carbon

The Carbon Profile Chart displays %Carbon (Y axis) vs Depth (X axis).

Title

In RealTime and Replay Modes, displays Load Name and Model Name.

- In Simulation mode, displays "Model Name - Segment Name"

Y Axis X Axis Cursor Position Target Profile Lab/Other Profile Mouse Mode Restore Button Message box Carbon Profile Initial Carbon Profile Target Profile Lab/Other Profile Saturation Carbon

- %Carbon

- Depth (in inches or mm depending on model settings)

- displays the %Carbon at Depth corresponding to the cursor crosshair position.

- check to display the target profile.

- check to display the Lab or other imported profile.

- places mouse in either cursor or zoom mode (default is cursor).

- used to restore the chart after using the zoom mode.

- message display.

- primary display (filled Blue) Carbon vs Depth

- Uniform or Custom Initial Carbon Profile (Lined Cyan)

- Maroon line indicating the "spec" or Target Profile

- Green line indicating the imported Lab or other imported Profile.

- Red Line indicating the "saturation" carbon for the given furnace temperature.

2.5 Users and Security

2.5.1 Login

Previous versions of CarbCalcII did not require Login or passwords. This version may be used to control furnace cycles in a production environment and therefore requires some protection. For each authorized user a User Name, Password and Access Level are maintained. When a user successfully logs in, he is granted access to program features depending on Access Level, Run Mode and Run Status.

A Login remains valid until 1) User Logs out or 2) In RealTime Control with program running Login is valid for 15 minutes.

There are 6 Access Levels (0 through 5):

Level 0 - Guest

access to simulation modes

cannot save or create models, parts, or loads

Note: This is the default User Level

Level 1 - Basic Operator

Access level 0 plus

can start and stop realtime loads

Level 2 - Advanced Operator

Access level 1 plus

can save and create loads, parts and models

Level 3 - Supervisor

Access Level 2 plus

can add and edit Material in the Material database

Note: This is the default User Level for BatchMaster Integration

Level 4 - Advanced Supervisor

Access level 3 plus

Level 5 - Administrator

Access level 4 plus

Manage User accounts

Unrestricted access to all features

CarbCalcIICarbCalc II15

To Login, click on the User Name Display/Login button. The Login dialog will open as shown above.

Enter User Name (not case sensitive)

Enter Password (this is case sensitive)

Click Enter

Successful Login - User name will be displayed in the User Name Display with a green background.

Unsuccessful login - message and Guest will be displayed as user name.

Click Cancel to logout (reverts to Guest)

Password restrictions:

Password cannot be blank

Password must be 3 or more characters or numbers

Password cannot be the same as user name (indicates reset)

Setting or changing a password. Only the Administrator can "reset" your password. When it is reset, the password is set to the User Name. When you logon, you will be prompted to enter a new password. If you forget your password, the Administrator can access it.

2.5.2 Manage Users

Only the Administrator (Access Level 5) can access the User's screen.

CarbCalcIICarbCalc II 16

When you login as Administrator, the buttons at the bottom of the login dialog will change to "Manage Users" and "Continue". Click continue to complete the login normally. Click "Manage Users" to show the Users Dialog.

Personnel Grid - Use the grid to Add, Edit or Delete Users.

Show Password - click and hold to display password for selected user.

Reset Password - click to reset the selected user's password. When reset, the password becomes the User Name and must be changed on next login.

2.6 Parts and Loads

2.6.1 Loads

CarbCalcII comes with a Part and Load database. The user interface with the database varies depending on the operating mode,

CarbCalcII in Control Mode - Loads and Parts integrated with Load Entry System.

CarbCalcII in Monitor Mode - Loadfs and Parts for display and replay of data.

CarbCalcII integrated with BatchMaster - BatchMaster Load database used for display and replay of data.

2.6.2 Control Mode

The Parts and Loads dialog contains 3 tabs: New Loads, Completed Loads and Parts.

CarbCalcIICarbCalc II17

New Loads

select a load to run. (Note: Yous must be logged in with access level 2 or higher to use this screen)

- This tab is used to build loads and add them to the Loads database. It is also used to

Load Name

load or type in a new name for a new load. The drop list will only display loads that have not been completed.

Load Part

associated with that part.

Qty

- enter the quantity of parts in this load.

Operator

Load Remarks

Model

changed using the droplist)

- A unique name to identify the Load. You may use the drop list to select an existing

- Select a part for the load (when a part is selected, the Model will change to the model

- (optional) enter an identifier for the operator

- Optional remarks

- Select the model to use for this load (model is selected when you select a part, but may be

Save Load

Select Load

- Click to save the Load in the database (does not select the load for execution)

- Click to select the load for execution (also saves the load to the database)

2.6.2.1 Entering a Load

In the Control Mode, you may enter a new load and either "Save" it for later use or "Select" it for current operations.

CarbCalcIICarbCalc II 18

Steps to Enter and execute a Load in Realtime Control Mode

1. Select Realtime Mode (the run button changes to 'Load Entry")

2. Click on "Load Entry" to open the New Loads dialog

3. Select a Load and click on the Select Load button

4. The button changes from "Load Entry" to Start Recipe.

5. At this point you should verify the recipe, profile, material etc. You may switch to "Simulation" and make simulation runs before starting the recipe in RealTime control.

6. Make sure the furnace is physically loaded.

7. Start the recipe. When the recipe is running, the computer is sending setpoints to the Carbon and Temperature controllers. Ath this point, CarbCalcII and the CarbCalc computer are dedicated to controlling the recipe. If you attempt to stop CarbCalcII you will get a warning message.

2.6.2.2 Load History in Control Mode

The Completed Loads Tab may be used to select loads for "Replay". Note: This tab is not available when a load is active in control mode.

CarbCalcIICarbCalc II19

The Completed Load Tab is displays a grid of loads, most recently completed on top. The "Time In" is stamped when the "Start Recipe" button is pressed and the "Time Out" is stamped when the load is completed ("unloaded"). These times may be edited on this screen with the appropriate access level. With appropriate access level, Loads may be edited, added or deleted from the database using the grid view.

To replay a load, select the load with the arrow indicator and click on the "Set Selected Load" button.

2.6.2.3 Parts in Control Mode

The Parts Tab is used to associate parts with models.

CarbCalcIICarbCalc II 20

Select/Enter Part

Description

Select Model

Save

Note: A Model is a set containing the "Material", "Target Profile" and "Recipe". Models are normally developed using CarbCalcII in the Simulation Mode.

- save changes

- enter/edit a part description.

2.6.3 Monitor Mode

The Parts and Loads dialog contains 3 tabs: New Loads, Completed Loads and Parts. In the Monitor Mode, there is no control of the process. However, Loads may be manually added to the loads database and replayed using SuperData's logged process data.

New Loads

(Note: Yous must be logged in with access level 2 or higher to use this screen)

- This tab is used to create loads and add them to the Loads database.

- Select an existing part or enter a new part name.

- Select the model to use when loading this part.

CarbCalcIICarbCalc II21

Load Name

Load Part

associated with that part.

Qty

- enter the quantity of parts in this load.

Operator

Load Remarks

Model

changed using the droplist)

Select Furnace

logged process data).

Start Date and Time

End Date and Time

date and time initializes to the start date and time)

Save Load

Select Load

In the Monitor Mode, the Mode.

- A unique name to identify the Load.

- Select a part for the load (when a part is selected, the Model will change to the model

- (optional) enter an identifier for the operator

- Optional remarks

- Select the model to use for this load (model is selected when you select a part, but may be

- Select the furnace that ran this load (CarbCalcII must know where to get the

- Click to save the Load in the database (does not select the load for replay)

- Click to select the load for replay (also saves the load to the database)

2.6.4 BatchMaster Mode

BatchMaster Integration

The BatchMaster Mode, the Loads database is provided and maintained by an external application (normally AFC-Holcroft's BatchMaster system). In the BatchMaster Mode, CarbCalcII provides simulation for modelling and Load Replay for monitoring cycles. Since the external application provides the load information, parts, times, etc. the "

Completed Loads

" tab is provided in the BatcfhMaster" mode.

- Enter the estimated Load Start date and time (may be edited later)

- Enter the estimated load end date and time (may be edited later). (Note: End

Completed Loads

mode is a special case of CarbCalcII's Monitor Mode. In the

Parts

and

New Loads

Tabs operate the same as in the Control

Parts

" and "

" tabs are not provided. Only the "

CarbCalcIICarbCalc II 22

See the "Configuration" section for setting up the BatchMaster Integration mode.

2.7 Model and Furnace Settings

2.7.1 Settings Overview

CarbCalcIICarbCalc II23

Settings dialog

The

model

The

Any model may be used with any furnace.

contains the "recipe segments", the material, the target profile, etc.

Furnace

contains data specific to a furnace.

2.7.2 Model Settings

is used to select the Model and the Furnace.

CarbCalcIICarbCalc II 24

Select Mode

Model Units

Measurement

Carbon Profile Chart

X Axis

Y Axis

Add New Model

will be saved with the current model settings. The settings may be subsequently changed and saved as desired.

Delete Mode

Save Model

model was last saved.

l - use this dropdown to select the desired model.

·Temperature - select Celsius or Fahrenheit

- select English or Metric

setting (Depth Axis) - Auto is recommended. setting (Carbon Axis) - Auto is recommended.

- Clicking this button will prompt you to enter a name for the new model, the model

l - clicking this button will delete the current model.

- will save the current model and all changes that may have been made since the

2.7.3 Furnace Settings

CarbCalcIICarbCalc II25

Select Furnace

Default Atmosphere Settings

Set Use Standard H2 to CO ratio 2:1

or Specify Custom H2 to CO ratio

Specify a Furnace Factor ( range 0.0 to 2.5 with normal value of 1.0 )

Probe Factor

- used by Marathon Instruments

COF

Furnace RealTime Setup

- use this dropdown to select the desired furnace.

- used by most instruments

- Clicking this button opens the RealTime setup dialog for the selected

furnace.

Add New Furnace

- Clicking this button will prompt you to enter a name for the new Furnace, the furnace will be saved with the current furnace settings. The settings may be subsequently changed and saved as desired.

Delete Furnace

Save Furnace

- clicking this button will delete the current furnace.

- will save the current furnace and all changes that may have been made since the

furnace was last saved.

2.7.4 Furnace RealTime Setup

CarbCalcIICarbCalc II 26

Furnace RealTime Settings

monitor/replay modes, they are not required for simulation mode. The realtime settings describe what information is available from the furnace instrumentation and where it can be accessed from SuperData. The realtime modes require SuperData communications and datalog system.

Installed Atmosphere control

Carbon Probe Controller

IR Analyze

Carbon Potential Determination

Temperature and %CH4 are always assumed to be model inputs.

Carbon and Probe Factor

Probe Millivolts and Probe Factor

Probe Millivolts and %CO

Analyzer).

%CO and %CO2

Data Sources

Data Name

Background color

Yellow - model input

Green - monitored but not used as model input

Blue - calculated value

Red - not used

Data Source

Select Data Source Dialog

r - select type installed or none.

- Uses %CO and %CO2 as model inputs (requires IR Analyzer).

- Displays the data source (SuperData channel and slot) for the models data values.

- name of the data value, Clicking on the Data Name opens the Data Source Dialog.

- displays the Channel, Slot and Multiplier location for the data value.

- The realtime settings are required for the realtime control and

- select yes or no.

- Select data values to be used as model inputs.·Note:

- Uses Carbon and Probe Factor as model inputs.

- Uses Probe millivolts and Probe Factor as model inputs.

- Uses Probe Millivolts and %CO as model inputs (requires IR

- the dialog is opened when you click on the Data Name. The dialog is

CarbCalcIICarbCalc II27

used to specify the data source values.

Chan

. - select the SuperData channel from the dropdown.

Slot

. - select the SuperData slot from the dropdown.

Default/Manual

- enter a default value - this value is used in the model when communications is lost, the value is also used as a manual input value when the data is not available and the channel is set to "(None)".

Multiplier

- SuperData data is always stored as integer with implied decimal points. e.g. 1.05 %C would be stored as 105, For this reason, it is necessary to provide a multiplier to retrieve the correct value. In the case of %Carbon, the multiplier is 0.01.

OK Button

- saves the changes for the current furnace (you must save the furnace settings to

make these changes permanent)

Cancel Button

- ignores any changes and exits the dialog.

Note: When in Control mode, you will also be prompted to supply the Setpoint Write

Locations.

2.8 Material Selection

2.8.1 Material Dtabase

Material database

The Additional material may be added to the database. The Probe Factor calculated by the model takes into account the composition of the steel. The %Carbon in the steel is used to set the initial Carbon Profile for the model (uniform).

dialog allows selection of most standard material for the given model.

CarbCalcIICarbCalc II 28

Material grid

Material Shape

Material Thickness

Set Custom Profile

normally used for modeling re-work where the Initial Carbon Profile is no longer uniform as in new steel.

Add New Material

OK Button

- Use the row selector to select the desired steel.

- select from Flat, Concave or Convex (not implemented - Flat is always used) .

- enter value, ( max value for the model is 1.0 inch or 25.4 mm )

- clicking this button opens the Custom Profile dialog. The custom profile is

- clicking this button opens the "Add New Material" dialog.

- applies changes to the current model and closes the material dialog.

CarbCalcIICarbCalc II29

The Add New Material dialog permits adding material to the database. You must specify a material name and composition.

2.8.2 Initial Carbon Profile

The Initial Carbon Profile is assumed to be uniform based on the %Carbon in the steel. This is the normal case for new product. In special circumstances, e.g. product to be re-worked, the Initial Carbon Profile may be substantially different.

Chart Area

Depth and %Carbon Columns

- displays the initial %Carbon vs Depth.

- Values in yellow background have been entered, values between

CarbCalcIICarbCalc II 30

entered values are interpolated and displayed with a white background. Surface and Max Model depth values are fixed.

Clear Set

Import Profile

- this button clears the yellow background for the Depth and %Carbon values respectively.

- permits importing (from a .tsv or .csv file) a carbon profile to be used as the initial

carbon.

Export Profile

- accepts changes and applies them to the current model. Note changes are not saved with the

- permits exporting the initial carbon profile to an excell compatible .tsv or .csv file.

model, the next time the model is loaded it will revert to uniform carbon for the selected material.

2.9 Target Profile

2.9.1 Specifying a Target Profile

The Target Profile is normally the specified goal for the simulation. The Target Profile is used to calculate excess and deficient Carbon during the "Auto Boost" segment and is used for curve matching in the "Auto Diffuse" segment.

Note: The Boost Diffuse Carbon cycle normally results in a profile that is "S" shaped. The principal points in describing the curve are:

Surface - surface %Carbon

Plateau - %Carbon at half of the effective case depth to produce an "s" shape curve.

Effective Case - Depth/Carbon for the effective case depth.

Total Case - Depth/Carbon for the total case depth (Carbon defaults to the %Carbon in the material).

Max Model - Always 1 inch (25.4 mm) with carbon the same as the material initial carbon.

CarbCalcIICarbCalc II31

Chart Area

Depth and %Carbon Columns

entered values are interpolated and displayed with a white background. Surface and Max Model depth values are fixed.

Clear Set

Import Profile

Profile.

Export Profile

Recommend Profile

- accepts changes and applies them to the current model.

- displays the Target Profile as %Carbon vs Depth.

- Values in yellow background have been entered, values between

- this button clears the yellow background for the %Carbon values.

- permits importing (from a .tsv or .csv file) a carbon profile to be used as the Target

- permits exporting the Target carbon profile to an excell compatible .tsv or .csv file.

- opens the "Recommend Profile" Dialog.

2.9.2 Recommended Profile

The Recommended Profile dialog permits easy entry of the target profile based on Surface Carbon,Carbon at the Effective Case Depth and Carbon at Total Case Depth.

CarbCalcIICarbCalc II 32

Edit Carbon and Depth values as desired

Cancel - ignores any changes and closes the dialog.

OK - Applies changes and closed the dialog.

2.10 Carbobn Profiles

2.10.1 Carbobn Profile Dialog

CarbCalcIICarbCalc II33

There may be up to 4 simultaneously displayed on CarbCalcII's Carbon profile chart:

Current Predicted Carbon - The model's current predicted carbon profile

Initial Carbon - The material's initial carbon profile

Target Carbon - The target or specification carbon profile

Lab/Other Carbon - An imported Carbon profile, may be from lab data or other source.

Clicking on the Carbon Profiles toolbar icon opens the Carbon Profile dialogue with the Target Profile active.

Clicking on the Active Profile Title box will switch the dialog to the next profile.

CarbCalcIICarbCalc II 34

Chart Area

Depth and %Carbon Columns

- displays the Active Profile as %Carbon vs Depth.

entered values are interpolated and displayed with a white background. Surface and Max Model depth values are fixed.

Clear Set

Import Profile

- this button clears the yellow background for the Depth or %Carbon values respectively.

- permits importing (from a .tsv or .csv file) a carbon profile to be used as the

selected Active Profile (Target, Initial or Lab).

Export Profile

Recommend Profile

- permits exporting the Active carbon profile to an excell compatible .tsv or .csv file.

- Values in yellow background have been "set", values between

- opens the "Recommend Profile" Dialog (Target Profile only).

- accepts changes and applies them to the current model.

CarbCalcIICarbCalc II35

2.11 SuperCalc

2.11.1 The SuperCalc Application

SuperCalc is an SSi Utility that aids in determining Carbon and Dewpoint based on Oxygen Probe or 3Gas IR analyzer. This utility is included with CarbCalcII and is also available on the web at SuperSystems.com

CarbCalcIICarbCalc II 36

2.12 Simulation Mode

2.12.1 Typical Uses

The Simulation mode provides a method for developing Carb Cycle recipes for Batch Furnaces. Typical uses include:

·Developing recipes for new product.

·Developing re-work recipes.

·Modifying existing recipes to potentially shorten furnace time. In the Simulation mode, model inputs are always Temperature, %Carbon, Probe Factor and %CH4. The Simulation Mode features various methods to model the End of Segment.

Timed segments

Match Surface Carbon

Match Carbon at a specified depth

Auto Boost

Auto Diffuse

CarbCalcIICarbCalc II37

Typical Steps in developing a Boost-Diffuse Carburizing Recipe

Select the Furnace

Select the Material

. Generate a Target Profile (Use recommended profile and modify as desired)

. Generate recipe segments

Usually 4 segments will be adequate (Come2Heat, Boost, Diffuse, Equalize)

Come2Heat - Soak for specified time

Boost - Use "AutoBoost" to end segment. %Carb should be just less than saturation for the given temperature.

Diffuse - Use "AutoDiff" to end segment. %Carb should be at or slightly above the Target Profile Surface Carbon.

Equalize/Cool - Timed Soak

. Run Simulation and evaluate results.

. Modify model (steps 2,3 and 4 above) and repeat simulation.

. When satisfied with simulation results, make a product test run,

. Compare test run lab results with simulation results (may use "Lab Profile" to aid in comparison).

. May be necessary to adjust the "Furnace Factor" to correct for differences in Lab Profile and

Simulation Profile.

Note 1:

Note 2:

When developing a "re-work" recipe, you will need to modify the "Initial Profile", all other

steps remain the same.

When modifying an existing recipe, replace the 4 segment cysle in step 4 with your existing

recipe.

2.12.2 Report

In the simulation mode, clicking on the print icon will print the following report. The report is a snapshot of the current model status and can be printed at any time during the simulation.

CarbCalcIICarbCalc II 38

2.13 RealTime Control Mode

2.13.1 Typical Uses

In the RealTime Control Mode, a Carb Cycle may be controlled via SuperData Communications. Typical uses include: Controlling a Carbon Cycle Recipe and monitoring the Carbon Profile in RealTime

In the RealTime mode, Model inputs include Temperature and %CH4 and either Probe Data or IR Analyzer Data for Carbon Potential determination.

2.13.2 Report

In the RealTime Control mode, clicking on the print icon will print the following report. The report is a snapshot of the current model status and can be printed at any time during the run.

CarbCalcIICarbCalc II39

CarbCalcIICarbCalc II 40

2.14 Replay Monitor Mode

2.14.1 Typical Uses

The Replay/Monitor mode may be used to review potential probelms with a load and as an aid in determining what may have gone wrong. The Replay/Monitor mode may be used in conjunction with the RealTime control Mode or with Superdata Datalog and a manually maintained Loads Database, or with BatchMaster Integration using an external Loads database.

Replay Monitor in conjunction with the RealTime Control Mode.

The Replay mode is similar to the RealTime Control Mode. When a Carb Cycle is run in Control Mode, the following data is saved:

Load Information - in the CCLoads Database

Model as run - an "as run" model file is saved under the name "L-xxx-model.ccp" (where xxx=load id number and model=model name)

Logged Process data - SuperData Communications historically logged data.

Using this data, the Cycle can be selected from the CCLoads database and may be replayed.

CarbCalcIICarbCalc II41

Replay Monitor With SuperData and a Manual Database.

This method is used when the Control Mode is not used. This method requires that the RealTime Data Sources be configured for each furnace supported. This method also requires that a Load be

CarbCalcIICarbCalc II 42

manually entered using the Load Entry Screen. Load Entry must include a Load Start and Load End time.

Load Information - manually entered in the CCLoads Database

Model as run - after the first replay, an "as run" model file is saved under the name "L-xxx-model.ccp" (where xxx=load id number and model=model name)

Logged Process data - SuperData Communications historically logged data.

Using this data, the Cycle can be selected from the CCLoads database and may be replayed. During replay, the recipe will be displayed, but only the total time (not segment times) will be displayed. This is becaause the actual recipe used in the control instrument is unknown to CarbCalcII; only the logged data and start/ent times are known.

Replay Monitor With BatchMaster Integration and an External Database.

This method is used when an external Load Entry system and Database are used (e.g with BatchMaster or other Load Tracking systems). This method requires that the RealTime Data Sources be configured for each furnace supported. This method also requires that the External Database must be available through an ODBC DSN and that the carbcalc.ini file be configured for Load Database access (see configuration section).

Load Information - obrtained from an external Load Tracking Database

Model as run - initial replay uses default settings, saving the load settings saves an "as-run" model file for the load the name "BML-xxx-model.ccp" (where xxx=load id number and model=model name)

CarbCalcIICarbCalc II43

Logged Process data - SuperData Communications historically logged data.

Using this data, the Cycle can selected from the CCLoads database and may be replayed. During replay, the recipe will not be displayed; only the total time will be displayed. This is becaause the actual recipe used in the control instrument is unknown to CarbCalcII; only the logged data and start/ent times are known.

2.14.2 Report

n the Replay mode, clicking on the print icon will print the following report. The report is a snapshot of the current model status and can be printed at any time during the replay.

CarbCalcIICarbCalc II 44

3 CarbCalcII Configuration

CarbCalcII is supplied in a fully functional 30 day "Trial" version. To continue using CarbCalcII beyond the 30 day time limit, it must be registered and purchased from Super Systems Inc. Instructions for registering ar contained in the Help/About screen.

CarbCalcII will require some configuration at time of installation. CarbCalc

No configuration required

CarbCalc

Communications Data Sources must be configured for each furnace. (part of furnace settings)

Simulation

RealTime Control, Replay and Monitoring

mode

modes

CarbCalcII ConfigurationCarbCalc II45

CarbCalc.ini file :

This file will be located in the same directory that contains CarbCalcII.exe (the application directory). This file is used to configure some operating modes, and database locations and external database structure.

General

The

TID = xxxx (where xxxx = a 4 digit TrialID number. Do not remove this number, you may lose your

section

registration.)

RTMONITOR=x (where x=0 or 1. When set to 1, puts CarbCalc in a Replay/Monitor mode using CCLoads Database)

BMIntegration=x (where x=0 or 1. When set to 1, puts CarbCalc in a BatchMaster Monitor mode using and external Database)

Databases

The

Material=<name>.mdb (where <name> is the name of the material access database (default

carbcalc.mdb

CCLoads=<name>.mdb (where <name> is the name of the CarbCalc Load access database (default

section

if not specified)

CCLoads.mdb

if not specified) Note: the database names may be filename only (assumes file is in the application directory) or full path and filename.

BMLoads

The

DSN=<name> (where <name> is the ODBC DSN)

T_LOAD=<name> (where <name> is the table name for the table containing the load information)

F_ID=<name> (where <name> is the field name for the numeric field containing the load ID)

F_LNAME=<name> (where <name> is the field name for the character field containing the load

section (only required when BMIntegration=1, ignored otherwise)

Name)

F_FCE=<name> (where <name> is the field name for the character field containing the Furnace Name)

F_TIMEIN=<name> (where <name> is the field name for the datetime field containing the Load Start time)

F_TIMEOUT=<name> (where <name> is the field name for the datetime field containing the Load End time)

F_LINFO=<name> (where <name> is the field name for a character field containing additional Load Information)

F_COMMENTS=<name> (where <name> is the field name for a character field containing additional LoadComments)

Sample Carbcalc.ini file

[General] *trial ID TID= 9638 RTMONITOR=0 BMIntegration=1

[DataBases] Material=carbcalc.mdb CCLoads=C:\ssi\data\CCLoads.mdb

[BMLoads] DSN=BM1 T_LOAD=Loads

F_ID=LID F_LNAME=LoadNo F_FCE=FceName F_TIMEIN=StartDT F_TIMEOUT=EndDT F_LINFO=Recipe F_COMMENTS=Part

CarbCalcII ConfigurationCarbCalc II 46

Super Systems CarbCALC II User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Introduction

1.1 Welcome to SuperSystems

1.2 CarbCalcII Introduction

2 CarbCalcII

2.1 Overview

2.2 Typical Uses

2.3 Menu and Toolbar

2.4 Displays

2.4.1 Atmosphere Display Area

2.4.2 Model Segment Display Area

2.4.3 Segment Properties Dialog

2.4.4 Temperature and Carbon Chart

2.4.5 Carbon Profile Chart

2.5 Users and Security

2.5.1 Login

2.5.2 Manage Users

2.6 Parts and Loads

2.6.1 Loads

2.6.2 Control Mode

2.6.2.1 Entering a Load

2.6.2.2 Load History in Control Mode

2.6.2.3 Parts in Control Mode

2.6.3 Monitor Mode

2.6.4 BatchMaster Mode

2.7 Model and Furnace Settings

2.7.1 Settings Overview

2.7.2 Model Settings

2.7.3 Furnace Settings

2.7.4 Furnace RealTime Setup

2.8 Material Selection

2.8.1 Material Dtabase

2.8.2 Initial Carbon Profile

2.9 Target Profile

2.9.1 Specifying a Target Profile

2.9.2 Recommended Profile

2.10 Carbobn Profiles

2.11 SuperCalc

2.12 Simulation Mode

2.13 RealTime Control Mode

2.14 Replay Monitor Mode

3 CarbCalcII Configuration