Abstract
This paper presents an investigation of non-stationary induction heating process applied to AISI 4340 steel spline shafts based on 3D simulation and experimental validation. The study is based on the knowledge, concerning the form of correlations between various induction heating parameters and the final hardness profile, developed in the case of stationary induction heating. The proposed approach focuses on analyzing the effects of variation of frequency, power and especially scanning speed through an extensive 3D finite element method simulation, comprehensive sensitivity study and structured experimental efforts. Based on coupled electromagnetic and thermal fields analysis, the developed 3D model is used to estimate the temperature distribution and the hardness profile. Experimentations conducted on a commercial dual-frequency induction machine for AISI 4340 steel splines confirm the feasibility and the validity of the proposed modelling procedure. The 3D model validation reveals a great concordance between simulated and measured results, confirms that the model can effectively be used as framework for understanding the process and for assessing the effects of various parameters on the hardening process quality and performance and consequently leads to the most relevant variables to use in an eventual hardness profile prediction model.
Highlights
IntroductionOne of the best processes is induction hardening, which is used to bond, harden or soften metals or other conductive materials
This paper presents an investigation of non-stationary induction heating process applied to AISI 4340 steel spline shafts based on 3D simulation and experimental validation
The 3D model validation reveals a great concordance between simulated and measured results, confirms that the model can effectively be used as framework for understanding the process and for assessing the effects of various parameters on the hardening process quality and performance and leads to the most relevant variables to use in an eventual hardness profile prediction model
Summary
One of the best processes is induction hardening, which is used to bond, harden or soften metals or other conductive materials. Induction heating relies on radio frequency (RF) energy, so heat is transferred to the part via electromagnetic waves and the inductor itself does not get hot This leads to a highly repeatable and reliable process. According to Faraday’s Law, if the secondary coil of the transformer is located within the magnetic field, an electric current will be induced. These eddy currents flow against the electrical resistivity of the metal, generating localized heat This heating is called the Joule effect, referring to Joule’s first law. 3D modelling and simulation, structured experimental efforts and improved statistical analysis tools are used to evaluate the effects of power, frequency variation and scanning speed on the hardness profile. This will shorten the calculation time and the software efforts to give precise results [5] [6] [7] [8] [9]
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