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HARDENING PROCESS
PART 1: INDUCTION HEATING
http://me.wpi.edu/~camlab
Induction: Why Induction Heat Treatment?
Advantages
Practical Problems
• Lack of systematic heating time and temperature distribution control inside WP.
• Nonlinear effect of material properties.
• Lack phase transformation data inside WP for hardness and residual stress determination.
• Evaluate combination effect of AC power density, frequency and gap on final hardness pattern.
• Trial and error, cost and design period.
• Induction heating:
metal parts heated to
austenite Phase
•Fast quenching
process transforms
austenite to
martensite phase
workpiece Inductor/coil
Heating
•Martensite process
content determines
the hardness
Joule heat by
eddy current
•Martensitic
structure is the
most hardest Electromagnetic Induction High
microstructure field coil freq. AC
power
Principle: Electromagnetic and Thermal Analysis WP Coil
0 I dl
Calculation of
magnetic vector potential (A)
A
4 C r
T
Calculation of Qinduction = E J = J2/ c k 2T Qinduction
Inducting heat (Qinduction) t
T
Output:
Heat generation Qinduction in WP
c
t
k 2T Qinduction A F T 4 Tair4 A h T Tair
concave
Material: Carbon
Steel, AISI 1070
convex
Automotive parts from
Delphi Inc.,
Sandusky,Ohio
conductivity
WP relative Electrical
permeability Resistivity
Emissivity
Specific
heat
Convection
coefficient
Case Study: Magnetic Field Intensity Distribution
Effect of current density distribution
t=0.5s t=2s
Total heating time
th = 7.05s
f=9600Hz
s=1.27mm
J=1.256e6 A/m2
t=4s
Case Study: Heating Curves
Summary
• A finite element method based modeling system is developed to analyze the
coupled electromagnetic/thermal process in induction heating and
implemented in ANSYS package, with following capabilities.
• Provide electrical and magnetic field strength distribution.
• Provide instantaneous temperature field data in workpiece.
• Provide Temperature history at any location in heating process.
• Provide guidance for inductor/coil design based on adjustment of current
density distribution and desired heating patterns.