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

电磁场分析、热条件分析和弹性塑料压力分析，用统一交叉部分和肩轴输送轴的轴的加热和水冷却过程，以轴向FEM输送，考虑磁性渗透性的变化、抵抗力、热膨胀系数的协同作用和具有温度的磁场压力。对永久性压力和硬层进行了测试的优化硬化条件和线圈配置。已开发出一个3D-FEM程序，用于对感应电流密度、温度和压力进行计算，以确定感应硬化过程。固定压力和固定压力层的Gear due到单和双频率指示的硬件是根据FEM程序的标准计算的，然后是固定压力和固定压力层的硬件方法。主要结果从这一调查中获得的最佳温度可以归结为以下.1.A图表，以确定最佳温度 ... More g电功率P的条件和频率f对永久性压力的指示通过统一交叉部分的轴硬被衍生出来。2.有效的案例深度HV=550（Hv ： Vickers Hardness number）由于在轴的末端与轴的末端与轴的均匀交叉部分增加，在轴的中间和轴的末端与轴的收缩困难。（L-D2C-D2：coil length）.3. Axial and circumferential residual stresses D2z D2 D1 * D1，D2/D2/D2/D1* D1 of the shouldered shaft due to the induction using the coil with constant inner diameter变成较大的压缩压力，仅在轴表面的较小的直径在下f和轴表面的较大直径在情况下the case of higher f.4. Surface序列D2序列D1* 序列D1，序列D2序列D2序列D1* 序列D1 of the shouldered shaft become large compressive stresses along the length of the shaft by carrying out the dual f\induction hardening.5.Hardened layer of shouldered shaft occurs along the length of the shaft to certain shoulder height by carrying out the dual f\induction hardening，而且，对于较大的肩膀，线圈必须从较小的坐标轴末端溢出。6.在狭窄的表面宽度b的情况下，最大温度在最后的位置，加热过程的齿轮变成了表面宽度末端的牙齿底部，不符合P和f的情况下，但是，在Wider的情况下，B.7.Contour lines of Temperature at the End of Induction加热过程的中间面底部的底部和面部宽度的底部，以及更高的面部宽度的底部。牙齿剖面图由双重频率指示硬、永久压力和硬层围绕牙齿剖面图进行定位。Less（低）

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