Abstract
Induction hardening is an important manufacturing process to control the mechanical properties of metal parts where surface hardness is enhanced while the core retains the toughness. This paper presents the modeling and simulation of the induction hardening processes with the finite element analysis. A coupled electromagnetic-thermal analysis is applied to the induction heating process. The temperature distributions in parts are obtained in heating and quenching process. The induction heating and quenching are highly nonlinear processes because the materials properties of the parts are temperature dependent. The final hardening process involves the determination of martensite volume content and hardness value. An algorithm is utilized to determine the volume fraction of diffusion controlled metal phase transformation and martensite content. Finally, the hardness value is converted from martensite content. Results for a complex surface hardening are presented. The effects of input power, frequency and air gap on final hardened pattern are systematically studied.
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