Study on Residual Stress and Optimum Hardening Condition of Induction Hardened Gears

感应淬火齿轮残余应力及最佳淬火条件研究

• 批准号: 06555046
• 负责人: ODA Satoshi
• 金额: $ 2.75万
• 依托单位: Tottori University
• 依托单位国家: 日本
• 项目类别: Grant-in-Aid for Scientific Research (B)
• 财政年份: 1994
• 资助国家: 日本
• 起止时间: 1994 至 1996
• 项目状态: 已结题
• 来源: https://kaken.nii.ac.jp/grant/KAKENHI-PROJECT-06555046/
• 关键词: Gear; Induction Hardening; Residual Stress; Electric Current Density; FEM; Electromagnetic Field Analysis; Heat Conduction Analysis; Elastic-Plastic Stress Analysis; 曲げ疲労強度; 歯面強度

Temperatures during induction heating process of a shaft with uniform cross-section were calculated by FEM electromagnetic field analysis and heat conduction analysis method, considering changes of the magnetic permeability and the resistivity with the temperature, and measured. The validity of this FEM calculation program was confirmed by comparing the calculated temperatures with the measured ones. An electromagnetic field analysis, a heat conduction analysis, and an elastic-plastic stress analysis during induction heating and water cooling processes of shafts with uniform cross-section and with shoulder fillet, of the inner surface of thick-walled cylinder, of the worm gear, and of the spur external and the internal gear were carried out by the FEM,considering changes of the magnetic permeability, the resistivity, the thermal expansion coefficient, and the yield stress with the temperature. The effects of the electric power and the frequency on the temperature and the stress during … More the induction hardening process and the residual stress due to the hardening were examined.The main results obtained from this investigation are summarized as follows.1. The calculated temperatures during induction heating process of a shaft with uniform cross-section by the FEM program developed in this investigation agree well with the measured temperatures. 2. Amount of heat of surface of the part of major diameter of the shaft with soulder fillet due to induction heating is greater in the case of high frequency but smaller in the case of low frequency than that of the part of minor diameter. 3. Residual stresses sigma_Z^<**> and sigma_<rheta>^<**> in the axial and the circumferential direction of the surface of the part of major diameter of the shaft with shoulder fillet due to the induction hardening become large compressive stresses and sigma_z^<**> and sigma_<rheta>^<**> of the part of minor diameter small tensile stress in the case of high frequency, while sigma_z^<**> and sigma_<rheta>^<**> of both parts become compressive stresses in the case of low frequency. 4. The temperatures of the inner surface during induction heating process of the inner surface of a thick-walled cylinder are higher than those of the outer surface. The difference between temperatures of both surfaces increase with electric power and frequency. 5. Residual stresses sigma_z^<**> and sigma_<rheta>^<**> in the axial and the circumferential direction of the inner surface due to induction hardening of the inner surface of a thick-walled cylinder decrease with increasing electric power. 6. The difference between temperatures at the tooth tip and the tooth bottom during induction heating process of worm gear increases with electric power and frequency. 7. It should be taken into consideration in the strength design of gear tooth that the residual stress along the tooth surface due to the induction hardening of spur external and internal gear becomes tensile stress in some cases at the tooth bottom under the heating condition of high frequency and large electric power. 8. Induction hardening by dual frequency method is considered to be valid for a shaft with shoulder fillet and a spur gear. Less

采用有限元电磁场分析和热传导分析方法，考虑导磁率和电阻率随温度的变化，计算了等截面轴感应加热过程中的温度，并进行了测量。通过计算温度与实测温度的比较，验证了有限元计算程序的正确性。采用有限元法，考虑导磁率、电阻率、应变率等参数的变化，对等截面轴类、带圆角轴类、厚壁圆筒内表面类、蜗轮类、直齿内外齿轮类等零件感应加热水冷过程进行了电磁场分析、热传导分析和弹塑性应力分析，热膨胀系数和屈服应力随温度的变化。研究了电功率和频率对热处理温度和应力的影响 ...更多信息 本文研究了感应淬火工艺及淬火残余应力的变化规律，主要结果如下：1.利用所开发的有限元程序对等截面轴感应加热过程中的温度场进行了计算，计算结果与实测结果吻合较好。2.由于感应加热，具有较深圆角的轴的大直径部分的表面的热量在高频的情况下比小直径部分的热量大，但在低频的情况下比小直径部分的热量小。3.在<rheta>高频的情况下，由于感应淬火而在轴的具有台肩圆角的大直径部分的表面的轴向和周向方向上的残余应力σ_Z^**&gt;和σ_ ^**&gt;变为大的压应力，并且小直径部分的σ_z^**&gt;和σ_<rheta>^**&gt;变为小的拉应力，而在低频的情况下，两个部分的σ_z^**&gt;和σ_<rheta>^**&gt;变为压应力。4.厚壁圆筒内表面感应加热时，内表面温度高于外表面温度。两个表面之间的温度差随着电功率和频率而增大。5.由于<rheta>厚壁圆筒的内表面的感应淬火而导致的内表面的轴向和周向方向上的残余应力σ_z^**&gt;和σ_z ^**&gt;随着电功率的增加而减小。6.蜗轮感应加热过程中齿顶与齿底温度差随电功率和频率的增大而增大。7.直齿外、内齿轮感应淬火产生的沿齿面沿着的残余应力，在高频大功率加热条件下，在某些情况下在齿底变为拉应力，这是齿轮强度设计中应考虑的问题。8.双频法感应淬火被认为是有效的轴肩圆角和直齿圆柱齿轮。少

项目成果

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Yukitsu Miyachika：“感应淬火对轴残余应力的影响”日本机械工程师学会会议记录 95-10[IV]。

宮近幸逸: "軸の高周波焼入れ過程の温度・応力" 日本機械学会講演論文集. 955-1. 231-232 (1995)

Yukitsu Miyachika：“轴感应淬火期间的温度和应力”日本机械工程师学会会议记录 955-1 (1995)。

宮近幸逸: "Calculations of Temperature and Stress of Circular Bar during Induction Hardening" IACM WCCMIII The Third World Congress on Computational Mechanics Extended Abstracts. Vol.II. 1928-1929 (1994)

Yukitsu Miyachika：“感应淬火期间圆棒的温度和应力的计算”IACM WCCMIII 第三届世界计算力学大会扩展摘要，1928-1929 年（1994 年）。

宮近幸逸: "Calculations of Temperature and Stress of Circular Bar during Induction Hardening Process" IACM WCCM III The Third World Congress on Computational Mechanics Extended Abstracts. Vol. II. 1928-1929 (1994)

Yukitsu Miyachika：“感应淬火过程中圆棒的温度和应力的计算”IACM WCCM III 第三届世界计算力学大会扩展摘要 II。

Miyachika, Kouitsu: "Temperature and Stress of Shaft during Induction Hardening Process by Dual Frequency Method" Prepr.of Jpn.Soc.Mech.Eng.Vol.97-1 [IV]. 33-34 (1997)

Miyachika, Kouitsu：“双频法感应淬火过程中轴的温度和应力”Prepr.of Jpn.Soc.Mech.Eng.Vol.97-1 [IV]。