Multi-variant calculations of induction heating process

• Autorzy: Smalcerz A. , Przyłucki R. , Konopka K. , Fornalczyk A. , Ślezok M.
• Języki publikacji: EN

Abstrakty

EN

Purpose: Induction heating process is often used as the first stage of quenching process. Computer simulation of the induction heating make it possible to eliminate expensive and time-consuming experimental selection of parameters. The selection of appropriate heating parameters is particularly difficult for the irregularly shaped parts. Gears are an example of such elements. In the case of surface quenching / heating a uniform distribution of temperature field is necessary on the surface and expected temperature gradient inside the heated gear. The following parameters: inductor frequency, inductor power, heating time, inductor geometry, distance between inductor and heating gear and relative shift between inductor and gear have a significant effect on the temperature distribution. Obtaining the correct temperature distribution requires proper selection of the above mentioned parameters. Numerical optimization or multi-variant calculations are the best way to achieve the goal. Design/methodology/approach: This work presents numerical simulation of induction heating. Such simulation consists of an analysis of coupled electromagnetic and thermal fields. Commercial program Flux 3D, was used to perform the calculations. Findings: Execution of 10 variants of calculation enables to obtain the optimal values of the parameters influencing the heating process. Practical implications: During the test quenching of the gear a problem of non uniform temperature distribution appears. The attempts of experimental selection of heating parameters failed, and the problem was solved by multi-variant calculations. The results obtained from the calculations were successfully applied in the quenching process. Originality/value: This paper shows an application of numerical simulation in gear quenching. The results of simulations were practically verified.

Słowa kluczowe

EN

induction heating; quenching; coupled electromagnetic-thermal calculation; temperature measurement verification; gears

PL

nagrzewanie indukcyjne; hartowanie; przekładnie

• Wydawca: International OCSCO World Press
• Czasopismo: Archives of Materials Science and Engineering
• Rocznik: 2012
• Tom: Vol. 58, nr 2
• Strony: 177--181
• Opis fizyczny: Bibliogr. 14 poz.

Twórcy

autor

Smalcerz A.

• Managements and Informatics Department, Faculty of Materials Engineering and Metallurgy, Silesian University of Technology, ul. Krasińskiego 8, 40-019 Katowice, Poland

autor

Przyłucki R.

• Managements and Informatics Department, Faculty of Materials Engineering and Metallurgy, Silesian University of Technology, ul. Krasińskiego 8, 40-019 Katowice, Poland

autor

Konopka K.

• Institute of Measurement Science, Electronics and Control, Faculty of Electrical Engineering, Silesian University of Technology, ul. Akademicka 10, 44-100 Gliwice, Poland

autor

Fornalczyk A.

• Metallurgy Department, Faculty of Materials Engineering and Metallurgy, Silesian University of Technology, ul. Krasińskiego 8, 40-019 Katowice, Poland

autor

Ślezok M.

• University of Economics and Administration, ul. A. Frycza-Modrzewskiego 12, 41-907 Bytom, Poland

Bibliografia

• [1] V. Rudnev, D. Loveless, R. Cook, M. Black, Induction hardening of gears, a review, Heat Treatment of Metals 4 (2003) 97-103.
• [2] V. Rudnev, Induction hardening of gears, a review, Part 1, Heat Treatment of Metals, Wolfson Heat Treatment Centre, England, 2003, 97-103.
• [3] V. Rudnev, et al., Induction hardening of gears, a review, Part 2, Heat Treatment of Metals, Wolfson Heat Treatment Centre, 2004, 11-15.
• [4] G. Parris, D. Ingham, The submerged induction hardening of gears, Gear Technology, 2001, 28-40.
• [5] V. Rudnev, Systematic analysis of induction coil failures, Part 5, Effect of flux concentrators on coil life, Heat Treating Progress, 2006, 21-26.
• [6] M. Fisk, Simulation of induction heating in manufacturing, Licentiate Thesis, 2008.
• [7] R. Przyłucki, Calculations of the induction heating system with the monitoring of thermal stress in charge, Electrical Review 11 (2008) 210-214.
• [8] S. Lupi, F. Doughiero, M. Forzan, Modelling single- and double-frequency induction hardening of gear-wheels, Proceedings of the Conference EPM’2006, Sendai, 2006, 473-478.
• [9] M. Niklewicz, A. Smalcerz, The use of three-coil cylindrical inductor in the gear induction heating process, Electrical Review 5 (2010) 333-335 (in Polish).
• [10] J. Barglik, A. Kurek, D. Dołęga, et al., Induction hardening of gear wheels - numerical simulation, Proceedings of the 10th International Scientific Conference EPE, Czech Republic, 2009.
• [11] M. Niklewicz, A. Smalcerz, A. Kurek, Estimation of system geometry and inductor frequency importance in induction hardening process of gears, Electrical Review 11 (2008) 219-224.
• [12] J.R. Davis, Gear materials, properties and manufacture, ASM International, 2005.
• [13] Materials base: www.matweb.com.
• [14] Materials base: www.knovel.com/knovel2/default.jsp. [15] Flux3D v.9.1 User’s guide 2004.