针对16MnCrS5齿轮钢在淬火过程中易发生变形的问题，本工作结合实验与数值模拟方法，系统探讨其淬火变形机理。采用不同晶粒尺寸、组织带状化程度及淬透性的C型缺口试样进行淬火实验，测定了对应试样的淬火变形量。利用Deform有限元分析软件对上述试样在淬火处理过程中的温度场、应力场与相场进行模拟，可视化了其对应的淬火变形过程。结果表明，16MnCrS5齿轮钢的淬火变形量随晶粒尺寸和组织带状化程度的增加而增加，晶粒尺寸为75 μm的试样的淬火变形量相较于晶粒尺寸为22 μm的试样增加近一倍。当带状组织等级超过3级时，试样淬火变形量显著增加。16MnCrS5齿轮钢的淬火变形量随着淬透性的增加而增加，当试样距离水冷端9 mm处的硬度> 32.2 HRC时，淬火变形量与淬透性呈现更强的关联性。实验和数值模拟分析揭示16MnCrS5齿轮钢淬火热变形的内在机制主要归因于热应力和马氏体相变应力，其中，马氏体相变在时间和空间上的不均匀性是影响16MnCrS5齿轮钢淬火热变形的主要因素。

The 16MnCrS5 gear steel, known for its exceptional machinability and hardenability, is commonly utilized in the production of gears and worms in the automotive industry. However, the quenching process of this steel tends to provoke deformation, leading to increased wear and an inability of gear teeth to mesh. This issue seriously restricts the broader use of 16MnCrS5 gear steel. This study explores the quenching deformation of 16MnCrS5 gear steel through a combination of experimental research and numerical simulation to provide theoretical insight to mitigate this deformation in industrial production. The quenching deformations of C-notch samples derived from 16MnCrS5 gear steel, varying in grain size, banded structures, and hardenabilities were first measured. Subsequently, employing the deform finite element analysis software, the temperature field, stress field, and phase field during the quenching of these samples were simulated, thereby visually portraying the corresponding quenching deformation processes. The results indicate that the quenching deformation of 16MnCrS5 gear steel escalates with an increase in grain size and the proportion of banded structures. For instance, the sample with a grain size of 75 μm demonstrated nearly double the quenching deformation of the sample with a grain size of 22 μm. Moreover, when the grade of the banded structure surpasses 3, the quenching deformation of the sample markedly increases. Concurrently, the results revealed a positive correlation between quenching deformation and hardenability of 16MnCrS5 gear steel. Specifically, when the hardness at 9 mm from the quenching end (J9) > 32.2 HRC, the sample's core is largely martensitic, showing a stronger correlation with hardenability. Conversely, when J9 ≤ 32.2 HRC, there is noticeable bainitic transformation in the sample's core, resulting in a weaker correlation between the quenching deformation and hardenability. The experimental research and numerical simulations suggest that the intrinsic mechanism of quenching deformation in 16MnCrS5 gear steel is mainly attributable to thermal stress and martensitic transformation-induced stress. Notably, the temporal and spatial inhomogeneity of the martensite transformation in time and spatial distribution is the predominant factor affecting the quenching deformation of 16MnCrS5 gear steel.