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Study on Optimum Coil Design and Hardening Condition for Gear Induction Hardening

齿轮感应淬火最佳线圈设计及淬火条件研究

基本信息

批准号：
09650165
负责人：
MIYACHIKA Kouitsu
金额：
$ 2.24万
依托单位：
Tottori University
依托单位国家：
日本
项目类别：
Grant-in-Aid for Scientific Research (C)
财政年份：
1997
资助国家：
日本
起止时间：
1997 至 1999
项目状态：
已结题

来源：
https://kaken.nii.ac.jp/grant/KAKENHI-PROJECT-09650165/
关键词：
Gear Heating Coil Induction Hardening Shaft Induced Current Density Residual Stress Hardened Layer FEM

项目摘要

An electromagnetic field analysis, a heat conduction analysis and an elastic-plastic stress analysis during induction heating and water cooling processes of shaft with uniform cross-section and shouldered shaft were carried out by the axisymmetric FEM, considering changes of the magnetic permeability, the resistivity, the thermal expansion coefficient and the yield stress with the temperature. Optimum hardening condition and coil configuration for residual stress and hardened layer were examined. 3D-FEM program for calculations of induced current density, temperature and stress during induction hardening process was developed. Residual stresses and hardened layer of gear due to single and dual frequency induction hardening were calculated by means of the FEM program, and then optimum induction hardening method for residual stress and hardened layer of gear were examined.The main results obtained from this investigation are summarized as follows.1.A chart to determine the optimum heatin … More g condition of electric power P and frequency f for residual stress due to the induction hardening of shaft with uniform cross-section was derived.2.Effective case depth of Hv=550(Hv : Vickers hardness number) due to the induction hardening of shaft with uniform cross-section increase at the middle of shaft and decreases at the end of shaft with decreasing lィイD2cィエD2, P and F (lィイD2cィエD2 : coil length).3.Axial and circumferential residual stresses σィイD2zィエD2ィイD1*ィエD1, σィイD2θィエD2ィイD1*ィエD1 of the shouldered shaft due to the induction hardening using the coil with constant inner diameter become large compressive stresses at the shaft surface only of smaller diameter in the case of lower f and the shaft surface only of larger diameter in the case of higher f.4.Surface σィイD2zィエD2ィイD1*ィエD1, σィイD2θィエD2ィイD1*ィエD1 of the shouldered shaft become large compressive stresses along the length of the shaft by carrying out the dual frequency induction hardening.5.Hardened layer of shouldered shaft occurs along the length of the shaft to certain shoulder height by carrying out the dual frequency induction hardening, and for larger shoulder height the coil must be overhung from the shaft end of smaller diameter.6.The position of maximum temperature at the end of induction heating process of gear becomes the tooth bottom of the end of face width irrespective of P and f in the case of narrower face width b, but becomes the tooth bottom of the middle of face width for lower f and the tooth tip of the middle of face width for higher f in the case of wider b.7.Contour lines of temperature at the end of induction heating process become lines along tooth profile by carrying out the dual frequency induction hardening, and residual stress and hardened layer occur along the tooth profile. Less

考虑磁导率、电阻率、热膨胀系数和屈服应力随温度的变化，采用轴对称有限元法对等截面轴和带肩轴进行了感应加热和水冷却过程中的电磁场分析、热传导分析和弹塑性应力分析。对残余应力和硬化层的最佳硬化条件和线圈配置进行了研究。开发了感应硬化过程中感应电流密度、温度和应力的三维有限元计算程序。利用有限元程序计算了单频和双频感应淬火对齿轮的残余应力和淬硬层的影响，并对齿轮残余应力和淬硬层的最佳感应淬火方法进行了研究。本研究的主要结果总结如下：1。给出了确定均匀截面轴感应淬火残余应力的最佳加热条件P和频率f的图表。2 .有效壳体深度Hv=550（Hv：维氏硬度数），由于轴的感应硬化，具有均匀截面，轴中部增大，轴末端减小，P和F （l′′c′c′c′F：线圈长度）减小。轴向和周向残余应力σィイD2zィエD2ィイD1 *ィエD1,σィイD2θィエD2ィイD1 *ィエD1承担的轴由于不断使用线圈的感应淬火内径成为大压应力轴表面只有较小的直径的降低f和大直径的轴表面只有在更高的无。4 .经双频感应淬火后，沿轴长方向，轴肩表面的σ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ γ。通过双频感应淬火，沿轴长至一定的肩高处形成带肩轴硬化层，当肩高较大时，线圈必须从直径较小的轴端伸出。在面宽b较窄的情况下，无论P和f如何，齿轮感应加热结束时的最高温度位置都变为面宽末端的齿底，而在面宽b较宽的情况下，f较低时变为面宽中间的齿底，b较宽时f较高时变为面宽中间的齿尖7。通过双频感应淬火，感应加热过程结束时的温度轮廓线沿齿形形成线，沿齿形产生残余应力和硬化层。少