Influence of Induction Hardening Process on Camshafts’ Residual Stresses

2020 ◽  
Vol 45 (11) ◽  
pp. 9651-9659
Author(s):  
Honggen Zhou ◽  
Donghao Zhao ◽  
Yunlong Liu ◽  
Guochao Li
Keyword(s):  
Residual Stresses ◽  
Induction Hardening ◽  
Hardening Process

Effect of Preheat on Improving Beneficial Surface Residual Stresses During Induction Hardening Process

2016 ◽  
Author(s):  
Zhichao (Charlie) Li ◽  
Andrew Freborg ◽  
Lynn Ferguson
Keyword(s):  
Residual Stresses ◽  
High Cycle Fatigue ◽  
Induction Hardening ◽  
Heating Time ◽  
Single Shot ◽  
Cycle Fatigue ◽  
Steel Component ◽  
Hardening Process ◽  
Surface Residual Stresses ◽  
Residual Compression

Applications of the induction hardening process have been gradually increasing in the heat treatment industry due to its energy efficiency, process consistency, and clean environment. Compared to traditional furnace heating and liquid quenching processes, induction hardening is more flexible in terms of process control, and it can offer improved part quality. The commonly modified parameters for the process include the inductor power and frequency, heating time, spray quench delay and quench severity, etc. In this study, a single shot induction hardening process of a cylindrical component made of AISI 4340 is modeled using DANTE®. It is known that the residual stresses in a hardened steel component have a significant effect on high cycle fatigue performance, with higher magnitudes of surface residual compression leading to improved high cycle fatigue life. Induction hardening of steel components produces surface residual compression due to the martensitic transformation of the hardened surface layer, with a high magnitude of compression preferred for improved performance in general. In this paper, a preheat concept is proposed with the induction hardening process for enhanced surface residual compression in the hardened case. Preheating can be implemented using either furnace or low power induction heating, and both processes are modeled using DANTE to demonstrate its effectiveness. With the help of computer modeling, the reasons for the development of residual stresses in an induction hardened part are described, and how the preheat can be used to improve the magnitude of surface residual compression is explained.

Induction Hardening Process With Preheat to Eliminate Cracking and Improve Quality of a Large Part With Various Wall Thickness

2017 ◽  
Author(s):  
Zhichao (Charlie) Li ◽  
B. Lynn Ferguson
Keyword(s):  
Residual Stresses ◽  
Wall Thickness ◽  
Eddy Currents ◽  
Induction Hardening ◽  
Case Depth ◽  
Internal Stresses ◽  
Quench Rate ◽  
Process Modification ◽  
Hardening Process ◽  
High Magnitude

During an induction hardening process, the electromagnetic field generated by the inductor creates eddy currents that heat a surface layer of the part, followed by spray quenching to convert the austenitized layer to martensite. The critical process parameters include the power and frequency of the inductor, the heating time, the quench delay time, the quench rate, and the quench time, etc. These parameters may significantly affect case depth, hardness, distortion, residual stresses, and cracking possibility. Compared to a traditional hardening process, induction hardening has the advantages of low energy consumption, better process consistency, clean environment, low distortion and formation of beneficial residual stresses. However, the temperature gradient in the part during induction hardening is steep due to the faster heating rate of the surface and the aggressive spray quench rate, which leads to a high phase transformation gradient and high magnitude of internal stresses. Quench cracks and high magnitude of residual stresses are more common in induction hardened parts than those of conventional quench hardening processes. In this study, a scanning induction hardening process of a large part made of AISI 4340 with varying wall thickness is modeled using DANTE. The modeling results have successfully shown the cause of cracking. Based on the modeling results, a preheat method is proposed prior to induction heating to reduce the in-process stresses and eliminate the cracking possibility. This process modification not only reduces the magnitude of the in-process tensile stress, but also converts the surface residual stresses from tension to compression at the critical inner corner of the part, which improves the service life of the part. The modified process has been successfully validated by modeling and implemented in the heat treating plant.

scholarly journals Residual Stresses in Case Hardened Materials

2010 ◽  
Vol 4 (1) ◽  
pp. 92-102
Author(s):  
K. Palaniradja ◽  
N. Alagumurthi ◽  
V. Soundararajan
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Fatigue Behavior ◽  
Induction Hardening ◽  
Case Depth ◽  
Micro Hardness ◽  
X Ray Diffraction ◽  
X Ray ◽  
Hardening Process ◽  
Gas Carburizing

Fatigue behavior of case hardened parts depend to a great extent on the type of residual stresses developed in the components. Topography and metallurgical effects were the two elements which contribute much to surface integrity. Micro hardness of the gas carburized (EN 33 and EN 36) and Induction hardened (AISI 1040 and AISI 6150) specimens obtained during experiments, showed that there was gradual decrease of hardness from surface to sub-surface. Results also showed that more the hardness and case depth, the more was the residual stress. The optimum results gave the maximum compressive residual stress in both the gas carburizing and Induction hardening process irrespective of the mechanisms involved in the process. The X-ray diffraction test showed that the distribution of residual stress was uniform both on the surface and beneath the surface. The magnitude and distribution of residual stress obtained from the experiment agreed with the FEM results found in literatures.

Implementation of HMI Using VISUAL BASIC .NET for Induction Hardening Process

2019 ◽  
pp. 913-920
Author(s):  
Himanshu Sharma ◽  
Roushan Kumar ◽  
Adesh Kumar ◽  
Mukul Kumar Gupta ◽  
Vivek Kaundal
Keyword(s):  
Induction Hardening ◽  
Visual Basic ◽  
Hardening Process
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