Induction Heat Treatment Process Research Articles

Effect of Induction Heat Treatment Process and Graphene/B4C Amount on the Tribological and Mechanical Properties of Al6061 Hybrid Composites

Effect of Induction Heat Treatment Process and Graphene/B4C Amount on the Tribological and Mechanical Properties of Al6061 Hybrid Composites

Numerical simulation on induction heat treatment process of a shaft part: Involving induction hardening and tempering

An induction heat treatment process involving induction hardening and subsequent tempering was simulated based on the proposed electromagnetic-thermal-transformation-mechanical coupled numerical model. The isoconversional model and K–M equation were implemented to describe the phase transformation. The thermomechanical effect was calculated with consideration of transformation and creep. The temperature, microstructure and stress evolutions of a shaft part of SAE 4140H steel were simulated for different induction heat treatment processes. The corresponding experiments were performed to validate the proposed model. Comparison results of microstructure and residual stress indicated that the simulations fit well with the experimental results. The effects of transformation and creep on tempering stress relaxation were also analyzed based on the proposed numerical model.

Modelling and optimisation of electromagnetically coupled solid manufacturing processes

Electromagnetically-coupled manufacturing processes cover a wide range of applications - such as magnetic pulse forming processes or induction heat treatment processes. This paper presents a computational model and numerical tool developed in our laboratory for modelling these processes taking into account their specificities.

Modelling and optimisation of electromagnetically coupled solid manufacturing processes

Electromagnetically-coupled manufacturing processes cover a wide range of applications - such as magnetic pulse forming processes or induction heat treatment processes. This paper presents a computational model and numerical tool developed in our laboratory for modelling these processes taking into account their specificities.

Technologies advancing scan and single-shot induction hardening capabilities

This paper presents recent inverter and inductor innovations that have advanced the performance and capability of modern scan and single-shot induction hardening equipment. The physics and critical design elements of both of these induction heat treatment processes are discussed in detail and practical case studies featuring numerical computer simulation are referenced throughout.

Metallurgical and mechanical implications of inductor and process design factors in induction heat treatment

The selection and manipulation of inductor and process design parameters markedly affect the metallurgical and mechanical results of induction heat treatment processes. The primary purpose of this paper is to provide an overview of these critical design factors and to discuss their scope and method of influence. A practical case study illustrating the extent to which these design factors can impact heat treatment results is considered and analysed in detail, from concept to final results. Computer simulation is leveraged throughout to clearly and quantitatively demonstrate the implications of inductor and process design.

A New Approach in Optimizing the Induction Heating Process Using Flux Concentrators: Application to 4340 Steel Spur Gear

The beneficial effects of using flux concentrators during induction heat treatment process of spur gears made of 4340 high strength steel is demonstrated using 3D finite element model. The model is developed by coupling electromagnetic field and heat transfer equations and simulated by using Comsol software. Based on an adequate formulation and taking into account material properties and process parameters, the model allows calculating temperature distribution in the gear tooth. A new approach is proposed to reduce the electromagnetic edge effect in the gear teeth which allows achieving optimum hardness profile after induction heat treatment. In the proposed method, the principal gear is positioned in sandwich between two other gears having the same geometry that act as flux concentrators. The gap between the gear and the flux concentrators was optimized by studying temperature variation between the tip and root regions of gear teeth. Using the proposed model, it was possible identifying processing conditions that allow for quasi-uniform final temperature profile in the medium and high frequency conditions during induction hardening of spur gears.

Shape Rolling Process Combined with In-line Induction Heat Treatment for Rectangular Wire Die Springs

In recent years, environmental issues and high labor costs have been receiving increasing attention. One example is the manufacturing process of conventional oil tempered shaped wire which is high cost, time-consuming and polluting. The aim of this study is therefore to attempt to solve the problems of producing this particular form of wire. In this study we investigate the shape rolling process combined with the in-line induction heat treatment process for tempered trapezoidal wire. The round wire was heated to austenitic temperature using in-line induction heating equipment, and the wire was formed into a trapezoidal shape using a tandem cantilever type rolling mill, then quenched in water and tempered. The entire sequence was carried out in a single procedure with an automated line, the above-mentioned shape rolling process was verified by means of the finite element method, and finally the tempered trapezoidal wire was coiled to a helical form, i.e., rectangular wire die springs, which then underwent fatigue testing. The results revealed that the mechanical properties and the fatigue testing results of the die springs all satisfied industrial standards. The advantages of the manufacturing process of this study are that is highly efficient, low cost, and more environmentally friendly than the conventional process.

Numerical optimisation for induction heat treatment processes

This paper aims at introducing new approaches for designing and optimising induction heat treatment processes. Although the final objectives of induction heating processes may deal with some specific mechanical or metallurgical properties for manufactured parts, we shall primarily focus here on achieving an accurate control of temperature distribution and evolution in the Heat Affected Zone (HAZ). This objective can be formalised as a classical optimisation problem: we seek to minimise a cost function which measures the difference between computed and goal temperatures – along with some constraints on process parameters. We deal here with both zero-order algorithms – using a method based on Efficient Global Optimization algorithm which is an optimisation procedure assisted by a meta model – as well as first-order algorithms. These algorithms have been coupled with 2-D and 3-D finite element models developed in our laboratory; this model is based on a coupling procedure between Maxwell equations and heat transfer models, and has been extended to mechanical and metallurgical computations.

Development and application of computer simulation code COSMAP on induction heat treatment process

Induction heating reduces energy consumption, contributes to the protection of the environment, and improves productivity. This paper describes the development and application of computer simulation of induction heat treatment considered with coupling of temperature field and magnetic field. In this paper, the developed simulation code COSMAP is introduced as a CAE software system for considering the design of induction heat treatment process. It covers all aspects of heat treatment simulation, from magnetic and electrical to thermal states, phase transformation, residual stresses including as well all metallurgical phenomena.

Finite-element simulation of moving induction heat treatment

An efficient finite-element procedure with a remesh scheme has been developed for the analysis of the moving induction heat treatment process, wherein relative motion occurs between the coil and the workpiece. In this procedure, the magnetic field is first simulated by using an updated mesh that tracks the moving coil position; the moving heat source within the workpiece material is derived from the magnetic field. The heat equation is then solved to obtain the temperature field created by the heat source. The procedure has been applied to calculate the temperature distributions in 1080 carbon steel cylinders during induction heating. The calculations have been validated by comparison with analytical solutions for the temperature distribution obtained using Green’s function methods. Finally, the temperature, residual stress, and microstructure distributions in quenched 1080 steel cylinders have been obtained using the finite-element procedure. Quenching of the heated cylinders, by both a moving cooling ring and a stationary liquid bath, has been analyzed. The finite-element procedure presented incorporates temperature-dependent material properties, phase transformations occurring in the 1080 steel, the change in magnetic permeability of the 1080 steel at the Curie temperature, and an elastoplastic stress model based on a mixed hardening rule. The simulation results demonstrate that the finite-element procedure could be applied to a variety of moving induction heat treatment problems to determine the residual stress and microstructure distributions in the heat-treated component. It also could be used in the design of process parameters and coils.