Analysis and simulations of multifrequency induction hardening

Hömberg, Dietmar; Petzold, Thomas; Rocca, Elisabetta

doi:10.1016/j.nonrwa.2014.07.007

Cited by 26 publications

(22 citation statements)

References 17 publications

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“…In SDF, medium frequency current and high frequency current are used simultaneously. Both currents are controlled independently and then output power can be regulated to control the hardening depth at the root and tip of the gear [8].…”

Section: Introductionmentioning

confidence: 99%

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Investigation of Heat Treatment of Gears Using a Simultaneous Dual Frequency Induction Heating Method

et al. 2015

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This paper presents the development of a simultaneous dual frequency (SDF) induction hardening apparatus for gear hardening process. First, 2D FE modeling for thermal-electromagnetic coupled field is introduced for gear hardening and the analytical results are investigated. By modeling the gear hardening as 2D FE model, we can calculate for the coupled field more efficiently. And optimum process parameters can also be found through this analysis. A real SDF heat treatment equipment is manufactured using analytical results like input frequency and gear hardening experiments are conducted. Through analysis and experiments, we can validate the performance of the developed machine.

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Section: Introductionmentioning

confidence: 99%

“…al. solved a 3D model for SDF induction hardening of steel using Maxwell's equations and ODE for volume fraction of austenite [8]. Wrona used commercial FE software (ANSYS)to study SDF induction heating for gears using a 3D FE model [13].…”

Section: Introductionmentioning

confidence: 99%

Investigation of Heat Treatment of Gears Using a Simultaneous Dual Frequency Induction Heating Method

et al. 2015

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“…Now we prove existence and uniqueness of the weak solution of (18) on each time step with the help of the theory of monotone operators [24,32]). (18) and (19)…”

Section: Fully Discrete T-scheme and Stability Estimatesmentioning

confidence: 99%

“…Some papers present various numerical schemes for computation [1,4,6,12,30]. Other papers study the well-posedness of the problem and give theoretical results [7,14,17,18,[33][34][35]. But up to now, there are few researches considering both a nonlinear constitutional relation B = B(H) and dependence of electric conductivity on the temperature.…”

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confidence: 99%

Fully discrete T‐ψ finite element method to solve a nonlinear induction hardening problem

Kang

Wang

Zhang

2020

Numerical Methods Partial

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We study an induction hardening model described by Maxwell's equations coupled with a heat equation. The magnetic induction field is assumed a nonlinear constitutional relation and the electric conductivity is temperature-dependent. The Tmethod is to transform Maxwell's equations to the vector-scalar potential formulations and to solve the potentials by means of the finite element method. In this article, we present a fully discrete Tfinite element scheme for this nonlinear coupled problem and discuss its solvability. We prove that the discrete solution converges to a weak solution of the continuous problem. Finally, we conclude with two numerical experiments for the coupled system.

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“…It strives to achieve "uniform" temperature distributions along the outer contour of gears by applying two input currents simultaneously [1,2] . The amplitude and frequency of both currents are regulated independently to control the hardening depth at the root and the tip of the gear teeth [3] . Obtaining the best combinations of the input frequencies and powers experimentally is very costly and time consuming .…”

mentioning

confidence: 99%

Investigation of heat treatment of gears using a simultaneous dual frequency inducting heating method

Yun¹,

Park²,

Koo³

et al. 2015

2015 IEEE Magnetics Conference (INTERMAG)

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A heat treatment of gears (increasing hardness in the surface layers of gear teeth) significantly enhances the quality and performance of gears in terms of resistance to ware and abrasion and fatigue strength . Recently, a simultaneous dual frequency (SDF) induction heating technology has emerged as the most effective and efficient heat treatment method . It strives to achieve "uniform" temperature distributions along the outer contour of gears by applying two input currents simultaneously [1,2] . The amplitude and frequency of both currents are regulated independently to control the hardening depth at the root and the tip of the gear teeth [3] . Obtaining the best combinations of the input frequencies and powers experimentally is very costly and time consuming . Thus, many researches have been concentrated on determining these parameters using simulation methods, but they require tremendous computational time and resources [4,5] . In an effort to reduce computational costs in determining SDF input parameters, this paper proposes a 2D FE modeling method, and it experimentally evaluates the heat treatments of gears using a SDF induction heating system with the parameters obtained with 2D FE analysis . Two physical phenomena of electromagnetic field and heat transfer should be considered in induction heating models . At each time step, the heat produced by the magnetic field of the medium frequency (MF) and the high frequency (HF) is calculated using the harmonics analysis . It is then assigned as a heat source for the transient heat transfer analysis . This algorithm continues to the end of the target time . Fig . 1 (a) shows the 2D FE induction heating model for a baseline gear used in this study (the number of teeth, module, pitch diameter and width of the gear are 18, 4, 72mm and 10mm, respectively) . For parametric studies, the frequencies from 3 kHz to 15 kHz for MF, 110 kHz for HF and currents from 2000 A to 8000 A were considered . Fig .1 (b) shows simulation results with isothermal plots for each case at 0 .1 sec . Generally, SDF heating can be completed less than 0 .5 sec . As shown in Fig . 1 (b), the isothermal lines of the 3 kHz case "uniformly" follow along the contour of the gear tooth, indicating that it would harden the surface layer of the gear tooth uniformly . For the cases with 10 kHz and 15 kHz, the heat is concentrated in the tip of the gear . Although 3 kHz is the best condition, it becomes faulty gear treatment after 0 .2 sec . So, it can be identified that process time is also an important factor . To study the effect of gear types, this study considered four different gears with the same outer diameter (Gear A-module: 2, tooth number: 38, pitch diameter: 76mm; Gear B-module: 2 .5, tooth number: 30, pitch diameter: 75mm; Gear Cmodule: 4, tooth number: 18, pitch diameter: 72mm; Gear D-module: 5, tooth number: 14, pitch diameter: 70mm) . For this study, the same input condition (HF=110 kHz, MF=3 kHz, I H =2000A, I M =8000A) was used for all gears . Fig .1(c) shows simulation results at 0 .1 ...

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Analysis and simulations of multifrequency induction hardening

Cited by 26 publications

References 17 publications

Investigation of Heat Treatment of Gears Using a Simultaneous Dual Frequency Induction Heating Method

Investigation of Heat Treatment of Gears Using a Simultaneous Dual Frequency Induction Heating Method

Fully discrete T‐ψ finite element method to solve a nonlinear induction hardening problem

Investigation of heat treatment of gears using a simultaneous dual frequency inducting heating method

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