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

• 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

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

采用轴对称有限元法，考虑导磁率、电阻率、热膨胀系数和屈服应力随温度的变化，对等截面轴和带肩轴感应加热和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。对残余应力和硬化层的最佳硬化条件和线圈结构进行了研究。开发了感应淬火过程中感应电流密度、温度和应力的三维有限元计算程序。本文用有限元程序计算了齿轮单频和双频感应淬火的残余应力和硬化层，并对齿轮残余应力和硬化层的最佳感应淬火方法进行了研究。主要结果如下：1.给出了确定最佳加热温度的图表; 2.给出了确定最佳加热温度的图表; 3.给出了确定最佳加热温度的图表; 4.给出了确定最佳加热温度的图表 ...更多信息 导出了等截面轴感应淬火残余应力的功率P和频率f的g条件（Hv：维氏硬度值）由于具有均匀横截面的轴的感应淬火，随着l_（max）D2c_（max）D2、P和F的减小，在轴的中部增加，在轴的端部减小。（l）第D2c条第D2条：线圈长度）。3.轴向和周向残余应力σ D2 z D2 D1* D1，σ D2θ D2 D1* 由于使用具有恒定内径的线圈的感应淬火而产生的带肩轴的压应力D1在f较低的情况下仅在较小直径的轴表面处变成大的压应力，而在f较低的情况下仅在较大直径的轴表面处变成大的压应力。4.双频感应淬火使带肩轴表面σ_（1/2）D_（2/2）D_（2/2）D_（2/2）D_（1/2）D_（1/2）D_（1/2）D_（1/2）沿着轴长方向产生较大的压应力; 5.双频感应淬火使带肩轴沿着轴长方向产生一定台肩高度的硬化层，6.在齿宽B较窄的情况下，无论P和f如何，齿轮感应加热过程结束时的最高温度位置都成为齿宽端的齿底，而在较宽的b值下，f值较低时，为齿宽中部的齿底，f值较高时，为齿宽中部的齿顶。7.感应加热过程结束时，温度等值线变为沿着线通过双频感应淬火对齿形进行淬火，残余应力和硬化层沿着齿形产生。少

项目成果

Miyachika,Kouitsu: "Effect of Side-Carburizing on Residual Stress of Case-Hardened Gears"Prepr. of Jpn. Soc. Mech. Eng.. Vol.99-1. 279-280 (1999)

Miyachika, Kouitsu：“侧面渗碳对表面硬化齿轮残余应力的影响”Prepr。

Miyachika,Kouitsu: "Effect of Side-Carburizing on Residual Stress of Case-Hardened Roller"Prepr. of Jpn. Soc. Mech. Eng.. Vol.955-1. 127-128 (1998)

Miyachika，Koutsu：“侧面渗碳对表面硬化滚子残余应力的影响”Prepr。

宮近 幸逸: "浸炭焼入れローラの残留応力に及ぼす側面浸炭の影響" 日本機械学会講演論文集. 995-1. 127-128 (1999)

Yukitsu Miyachika：“侧面渗碳对渗碳淬火辊残余应力的影响”，日本机械工程师学会会议记录 995-128 (1999)。

宮近幸逸: "平滑軸の高周波焼入れ過程の温度・応力"日本機械学会論文集(C編). 64-625. 3623-3629 (1998)

Yukitsu Miyachika：“光滑轴感应淬火过程中的温度和应力”，日本机械工程师学会汇刊（ed.C）64-625（1998 年）。

宮近 幸逸: "平滑軸の高周波焼入れ過程の温度・応力" 日本機械学会論文集(C編). 64-625. 3623-3629 (1998)

Yukitsu Miyachika：“光滑轴感应淬火过程中的温度和应力”日本机械工程师学会会议记录（ed.C）3623-3629（1998）。