A reliable numerical model able to predict the hardness profile would shorten process development. Cenos platform was recently launched to enable computeraided engineering for smaller companies focused on induction heating and. Aug 10, 2015 this article compares the traditional process of case hardening with induction hardening and proves that the induction technology is advantageous when it comes to the integration into manufacturing lines, high productivity, energy and resourcesaving production, flexibility of the material selection and reproducibility of the hardening results. Simulation of induction heating of steel billets for. Effects of induction heating process parameters on hardness. Induction hardening as common heat treatment process for highlystressed automotive components significantly affects the surface layer properties leading to a compressive residual stress condition and a local hardening of the material. Certain applications require steel parts to offer a combination of mechanical properties and high surface hardness. Electromagnetic induction hardening is an energyefficient, inline, heattreatment process widely used in automotive industry to surfaceharden automotive parts at the lowest possible cost. Fea simulation thermal analysis of induction hardening. Induction hardening definition of induction hardening by. Impressive closeshots show every little detail in the hardening process, from heating to cooling. The parts to be heat treated are placed inside a water cooled copper coil and then heated above their transformation temperature by applying an alternating current to the coil. Technical infomation induction hardening nagato heat. Induction heating is a case hardening process used to improve performance of machine components by producing a hard martensitic microstructure and high compressive residual stresses at the surface layer.
A strong alternating magnetic field surrounds a conductive metal piece, producing an electric current that creates heat in the surface of the material being treated. Fem modeling of induction hardening processes in steel. Effect of dimensional variation on induction process. Surface hardening or case hardening is the process of hardening the surface of a metal object while allowing the metal deeper underneath to remain soft, thus forming a thin layer of harder metal called the case at the surface. Microstructural relations hardness of austenitized parts depends mainly on chemical composition and quench medium desired microstructures for reaustenization finer bainite and martensite pearlite effect of carbon on hardness in plain carbon spheroidite steels for a induction hardening, b furnace hardening with water quench and c furnace hardening with water quench and temper.
The use of induction heating computer simulation software can promote substantial improvements in the performance and costeffectiveness of induction heating equipment, in addition to large. The most important characteristics of the material hardening process include the hardness value and the case depth, both of which are a measure of the hardness of the material,14. Computer simulation for induction heating is a powerful tool that enables engineers and scientists to investigate or design a physical system andor process using a virtual mathematical model. Influence of process parameters for induction hardening on. Computer simulation for induction processes and coil design. The 3d model used during this study is built basing on coupling between maxwells and. A special simulation program has been developed for the axially symmetric workpieces. Hardenability is the term used to describe the effect of various elements on the transformation characteristics of steels and the resultant microstructure after cooling from the austenitising or hardening temperature.
Induction hardening, using progressive heating and quenching, provides and economical way to process shafts or other parts. Hardening of steels surface hardening, nitriding, flame. Induction hardening scientific forming technologies corporation. Induction hardening and tempering advantages gh induction. Submitted 25 march 2003 a modeling system for analyzing the integrated induction hardening processes was developed based on a generalpurpose finite element program, with the capability to analyze the whole process from electro. By placing a conductive material into a strong alternating magnetic field, electric current can be made to flow in the material thereby creating heat due to the i 2 r losses in the material. Induction is a nocontact process that quickly produces intense, localized and controllable heat. Hardening applications induction hardening machine. Computer simulation of induction hardening sciencedirect. In fact, magnetic field h and magnetic induction field b are linked, in a given material, by the equation. Induction hardening scientific forming technologies. Thermal abstracta modeling system for analyzing the integrated induction hardening processes was developed based on a generalpurpose finite element program, with the capability to.
Easily process your cad files with cenos intuitive cad framework. The entire inductive hardening process is fully controlled using modern process monitoring software. A great insight into the work of an induction hardening specialist. The induction hardening systems and the tempering furnace comply with the cqi9 standard, which is necessary for the automotive industry concerning the evaluation of heat treatment processes. Oct 07, 20 you will be shocked when you find out what this machine does.
Effects of induction heating process parameters on. This short video illustrates induction hardening, presented by the induction heat treating corp. Induction hardening is a form of noncontact heat treatment that uses electromagnetic induction to produce heat in metal parts internally. Upon quenching, the metal undergoes martensitic transformation, significantly increasing its hardness. Induction hardening service, induction heating in india. Simulation of spline heated by scanning induction process. It is a surfacehardening process in which a thin surface section of a component of hardenable steel is heated rapidly by direct application of high temperature flame to a temperature above its upper critical temperature i. Simulation software for induction heating heat processing online. Induction hardening, induction heating, quenching, modeling, simulations, phase transformations, fem, lsdyna. Cenos 3d induction heating computer simulation software. On this channel you can get education and knowledge for general issues and topics. The process tool is an extension of the dual pulse induction hardening dpih process.
The main benefit of induction heating for hardening is that it takes just a few seconds. The analysis of an induction hardening process is a complex process because induction hardening is a combination of heat transfer, electromagnetic and metallurgical phenomenon. Usually, induction hardening is applied to metal parts which need to have great surface wear resistance, while at the same time retaining their mechanical properties. Optimization of process parameters in induction hardening. Opensource tool paraview is connected to the platform for the best post processing experience. In this process, certain parts of a metal are heated up, while others remain unheated. C and then cooled more or less quickly depending on the characteristics of steel in a medium such as oil, air, water, water mixed with soluble. Fem modeling of induction hardening processes in steel j. The aim of the stationary induction hardening was to vary the process parameters of two available generators 25 and 300 khz to give an effective hardness penetration depth depth to 400 hv1 in the centre of the hardened zone of 1.
Induction hardening process bluewater thermal solutions. Accurate process control is the effective way to ensure the properties reliability of. Principles of induction hardening and inspection valery rudnev, inductoheat inc. Induction heating hardening is a kind of quenching method which uses the principle of electromagnetic induction to cut the magnetic force line in alternating magnetic field and produce induction current on the surface. The induction heating is a surface heat treatment that exhibits some relevant industrial advantages. After the induction hardening process is achieved, the metal workpiece needs to be quenched in water, oil or air inorder to obtain specific properties of the surface layer.
Fea simulation thermal analysis of induction hardening process in case of aisi 1040 steel dr. Induction hardening on the vlc 100 ih vertical hardening machine for mass production. By progressively passing a steel shaft through a heating coil into a water quench, the outer skin can be heated, quenched, and hardened without affecting its core. With induction, only the part to be hardened is heated. In 2011, barka presented a sensitivity study using a comsol 3d model simulation for spur gear heated by induction process. Dec 20, 2004 the computer simulation of electromagnetic, thermodynamic and microstructural transformations in the treated workpiece is usually recommended for the exact definition of working parameters in process planning of the induction hardening processes. Surface hardening, a process that includes a wide variety of techniques table 1, is used to improve the wear resistance of parts without affecting the more soft, tough interior of the part.
Fett, dana corporation arthur griebel and john tartaglia, element wixom introduction metals can be heated by the process of electromagnetic induction, whereby an alternating magnetic. This combination of hard surface and resistance to breakage upon impact is useful in. The animation shows the prediction for carbon in the austenite matrix left, carbon in carbide form middle, and a relative carbide size right. The quenched metal undergoes a martensitic transformation, increasing the hardness and brittleness of the part. This makes induction hardening an excellent option for case hardening. Microstructural relations hardness of austenitized parts depends mainly on chemical composition and quench medium desired microstructures for reaustenization finer bainite and martensite pearlite effect of carbon on hardness in plain carbon spheroidite steels for a induction hardening, b furnace hardening with water quench and c furnace hardening with water quench and. Design and fabrication of inductors for induction heat treating rob goldstein, fluxtrol william stuehr, induction tooling micah black, tucker induction systems for induction melting and mass heating, the early induction heating coils were manufactured from copper tubing wrapped in multiple turns around a mandrel. Jun 03, 2018 induction hardening has several benefits over other hardening methods. Hardening is a process of heating followed by cooling generally fast for increase hardness and mechanical strength of steel. The first step in designing an induction hardening. Scanning, rotating, hf simulation, dc link choke, coil design. Cenos is a fem based engineering software for 2d and 3d simulation of induction heat treatment like induction heating, induction hardening, brazing, annealing and tempering of steel, aluminium, copper and other parts. To this end, the steel is heated to a temperature slightly higher than the upper critical between 850900. Induction hardening technology heico fastening systems.
Flame hardening process, advantages and disadvantages introduction to flamehardening. Determining the influence of process parameters on the. Simulation of spline heated by scanning induction process 3d model. Comparing induction hardening, case hardening 20150810. Hardening with induction induction heating applications. Diagnostic tool helps develop profile for induction hardening. In recent years a number of investigations has been put forward dealing with modelling and simulation of fatigue behaviour of different components coupled to the used process parameters for induction hardening e. Nitriding fundamentals, modeling and process optimization. Sort by date 1 the submerged induction hardening of gears marchapril 2001.
Advantages of induction heat treating induction heating systems provide a fast, efficient and economical method of heating any electrically conductive material to a precise temperature. Computer simulation for induction heating inductoheat. The steps for induction hardening and metallurgical phenomena and principles of heat treatment for such induction hardening are discussed. Induction hardening is a process used for the surface hardening of steel and other alloy components. Various process parameters, such as feed rate speed at which the induction coil moves, which is measured in mmsec, current, dwell time time. The substitution of induction hardening for furnace hardening may lead to savings of up to 95% of the energy used in the. Does somebody know a free femsoftware for induction heating. Induction heating is a non contact heating process which uses the principle of electromagnetic induction to produce heat inside the surface layer of a workpiece. The toothbytooth, submerged induction hardening process for gear tooth surface hardening has been successfully performed at david brown for more than 30 years. They varied the process parameters of induction hardening to give a constant hardness penetration depth.
Induction hardening process in hindisurface hardening methodsheat treatment duration. Induction hardening is a process of heating followed by cooling generally fast to improve hardness and mechanical strength of steel. C and then cooled more or less quickly depending on the characteristics of steel. Ultraglow induction hardening is a form of heat treatment in which a steel or cast iron part is heated by electromagnetic induction, immediately followed by rapid cooling quenching. Induction hardening is a type of surface hardening in which a metal part is induction heated and then quenched. Induction hardening is a form of heat treating where a metal part is heated by induction and then quenched. In 2011, barka presented a sensitivity study using a. Innovative induction hardening process with preheating. The equipment utilizes clean, readily available electric power to heat the entire surface of the work piece or selected specific areas.
The animation shows the use of dante heat treatment simulation software in modeling a low pressure carburization process of a high alloy steel with strong carbide forming elements e. Nitriding fundamentals, modeling and process optimization by mei yang a dissertation. Jul 18, 20 the possibility to manage stress and strain in hardened parts might be beneficial for a number of induction hardening applications. Induction hardening equipment and processes radyne. Induction hardening machine are used for hardening of various metals, in order to give the material a higher strength and wear resistance. Omaha steel partners with induction hardening and flame hardening experts to provide both rough and machined castings that will meet your needs. The use of induction heating computer simulation software can promote. In this study the induction hardening process is simplified as two steps. Induction hardening definition and meaning collins english.
Induction hardening and heat treating are ideal for a wide variety of applications in the transportation, aerospace, and energy industries, for processes such as through hardening and case hardening. Simulation of stress and strain for inductionhardening. To implement this, the steel is heated to a temperature slightly above than the upper critical between 850900. Induction hardening is used to selectively harden areas of a part or assembly without affecting the properties of the part. Using computer simulation, fluxtrol can analyze the impact of changes to the geometry of the workpiece, material of the workpiece, motion of the part relative to. Induction hardening machine on sales quality induction. Despite the accepted simplifications, the simulation results appear to reflect the real distribution of residual stress in the investigated spur gear after the induction hardening process. Cenos is finite element method fem based computeraided engineering cae software for 2d and 3d simulation of induction heat treatment.
In fact, the process is not energyconsuming compared to thermochemical processes such as carbonizing and nitriding because it allows generating high power and focusing it locally and during a short time to achieve hardness at the surface area without affecting the part core. Induction hardening machine are designed for surface hardening of external and internal surfaces of engineering and automotive components such as shaft, gear, cog wheel, etc. Another benefit is that it begins heating the surface of the material, rather than the core. The vertical pickup hardening machine vlc 100 ih developed by emag eldec induction gmbh is the companys first machine to implement induction hardening on the emag modular standard machine type. An appropriate and powerful way to take the stress and strain into account during the development of a process is to make use of. It is easier to control b ecause it is an electrical process rather than a combustion process. In this scanning induction hardening simulation, the steel shaft is heated by eddy currents, provided by a moving, twoturn copper coil. The surface of this 1055 steel shaft is austenitized to a predetermined depth. The most important of these benefits are the improvement of fatigue strength, avoidance of cracks, and minimization of distortion. This makes hardening the narrow internal diameter, thin wall parts and neighbouring areas of the hardened part possible which were said to be impossible because of the limitation on machines and difficulty of heatingcooling before. Induction heating simulation involves a set of mutually coupled nonlinear phenomena. Induction hardening uses induced heat and rapid cooling quenching to increase the hardness and durability of steel.
The induction heating market is small compared to other industrial sectors and there are only a few specialized simulation packages on the market that can be used for induction process and coil design. In some cases, these studies include also modelling and measurement of residual stresses developed during induction hardening. It makes it possible to consider the optimization of stress distribution by varying the process parameters using the provided approach to simulations. Sep 28, 2016 induction hardening process parameters visit induction hardening system. Modeling and sensitivity study of the induction hardening process. Residual stress distribution in an induction hardened gear. Local fatigue strength assessment of induction hardened.
Design and fabrication of inductors for induction heat. Thermal abstracta modeling system for analyzing the integrated induction hardening processes was developed based on a generalpurpose finite element program, with the capability to analyze the whole. Simulation software for induction heating 20190517 industrial. The induction heating process parameters of frequency, power and. Optimization of processing parameters in induction. A new casedepth estimation technique for inductionhardened.
287 676 1614 762 651 1639 496 1119 315 319 895 149 1521 471 56 1213 1077 120 134 52 1622 1561 322 644 210 1271 78 362 463 733 285