Real-time prediction method of carbon concentration in carburized steel based on a BP neural network

Gears are key components of mechanical transmission systems. They need to be carburized and quenched to meet the requirements of internal toughness and external hardness, to obtain higher hardness and wear resistance. Heat treatment engineers can calculate carbon concentration distribution through the finite element analysis method, facing the challenge of high computational cost and high memory requirements. To solve this problem, a real-time prediction method of 1D and 2D carburizing concentration based on a Back Propagation (BP) neural network (BPNN) is proposed. First, carburizing experiments were conducted to verify the accuracy of the carburizing numerical model. Then, by establishing an accurate carburizing model, 37,800 and 177,147 1D and 2D carburizing training samples were generated using the finite element model (FEM) method, respectively. Finally, for 1D carburizing, the average relative error of the training model on the test set is 0.2911%. For 2D carburizing, the average relative error of the reconstructed BPNN model on the test set was 0.4381%, and a real-time performance evaluation was performed. The carbon concentration prediction time for each set of process parameters is only 0.12 s, nearly 175 times faster than FEM calculation, which meets the accuracy and real-time requirements for real-time prediction of carburizing carbon concentration.