This paper present the results of mathematical modeling of induction hardening processes applied to workpieces with complex geometries. The simulation of heating and quenching problems is organized by coupled multi-physical analysis of electromagnetic, thermal and optionally structural processes. Different models and the developed strategy for their use for designing the induction systems are demonstrated on an example of leading wheel gear hardening.

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This paper describes the numerical simulation and investigation of the electrothermal processes in the induction system for hardening of cams and journals of camshaft. Hardening of the camshaft elements is carried out by one simple inductor of round shape due to shift of the camshaft axis inside it. During the process of the hardening of the cams, the camshaft is stationary, during the process of the hardening of the journals it rotates. The results of the investigations are presented in the form of the temperature distribution in the cam and the journal. The optimum parameters of the induction system are also given, at which the best temperature distribution in the elements of the camshaft is achieved.

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Automatic optimization can be applied for modern design of induction heating installations for diverse technological applications. One effective approach to couple numerical models with advanced optimization search codes has been developed. It was successfully applied for design of induction heaters for hardening of leading gear wheel. In the second described example, the required temperature profile over the height of chemical reactor has been reached using the developed tools as well. Extremely homogeneous temperature distribution and high energy parameters have been provided by using the developed tools of optimal design and the results are presented in the paper.