Optimization design and operating parameters of induction heat-ing system for hardening

The paper deals with the problem of optimizing the design and operating parameters of an induction heating system for surface hardening of a steel stepped shaft. The problem of optimal design of an inductor is formulated based on a nonlinear two-dimensional numerical model of coupled electromagnetic and temperature fields, developed in the ANSYS Mechanical APDL software. Alternance method of parametric optimization of systems with distributed parameters is used to optimize induction hardening system. MATLAB software has been used for developing parametric optimization subroutine, which was incorporated into the numerical ANSYS model to simulate a process of induction heating. Commonly used a multi-turn solenoid-style coil fabricated from rectangular copper tubing has been used as a hardening inductor. Besides that, an application of profiled copper turns has been investigated. Optimization of induction hardening system described above allows one to substantially improve heating uniformity and enhance metallurgical characteristics of as-hardened stepped shaft. Localized temperature surplus at an upper diameter shoulder has been minimized. At the same time, sufficient austenitization in the fillet area near stepped region (diameter transition) has been obtained.

Fault detection in rotor system by discrete wavelet neural network algorithm

This study identifies a method for detection of irregularities such as open cracks or grooves on a rotating stepped shaft with multiple discs, based on the wavelet transforms. Cracks are represented as reduction in diameter of shaft (groove) with small width. Single as well as multiple grooves are considered on stepped shaft at locations of stress concentration. Translational or rotational response curves/mode shapes are extracted from finite element analysis of rotors with and without grooves. Discrete and continuous 1D wavelet transforms are applied on resultant response curve or mode shapes. The results show that rotational response curves or mode shapes are more sensitive to shaft cracks and key contributors to identify the location of cracks than translation response curves or mode shapes. Discrete wavelet transforms are accurate enough to locate the groove of smaller size. Effectiveness of detection by wavelets transforms is analysed for single as well as multiple grooves with increase in groove depth. Increase in groove depth can be quantified by increase in wavelet coefficient, and it can be an indicator. White Gaussian noise with low signal-to-noise ratio is added to response curves and analysed for crack location identification. Intelligent techniques such as artificial neural networks are used to quantify the location and depth of crack. Discrete wavelet transforms coefficients are provided as input to the neural network. Feed forward artificial neural networks are trained with Levenberg–Marquardt back propagation algorithm. Trained networks are able to quantify the crack location and depth accurately.

A comparative analysis of hot and cold flashless forging of a stepped shaft using vertically-parted dies

Flashless forging is classified as a precise metal forming technology. The main advantages of this technology are the reduction of the flash allowance and the shortening of the manufacturing time by eliminating the flash trimming operation. The article presents the process of one-step forging of a stepped shaft made of aluminum with the use of split dies. The process was carried out in cold and hot metal-forming conditions. The forging process was analyzed numerically using the Simufact Forming 15.0 software. The geometrical parameters of the obtained product were analyzed, and the distribution of effective strain, temperature, and the standardized cracking criterion was determined. The process force parameters were also determined. Numerical tests were verified in real conditions with the use of a specially designed device for forging in vertical split dies. Comparison of hot and cold forging in vertical split dies is presented. The comparative analysis results have demonstrated that the hot forging process has more advantages than the cold forging process. The hot forging process ensures higher accuracy of forged parts.

Natural Frequency Analysis of a Jeffcott Rotor Having Stepped Shaft

The Rotating shafts are mechanical elements used to transmit power or motion. A shaft with a step or steps is widely used instead of a shaft with a fixed (non-variable) diameter when operating at high speeds. The aim of this research is to study the effect of the step amount and its location in the shaft on the natural frequencies of the Jeffcott rotor model. Analytical methods are used to find an approximate formulation to obtain the natural frequencies of the Jeffcott rotor model neglecting the shaft mass. Lagrange equations are used to develop dynamic equations assuming elastic shaft with steps carrying a disk. The finite element method by using ANSYS is used to validate and compare the results obtained in the analytical method. The results obtained analytically and numerically were compatible and in good agreement. In addition, some parameters such as the step amount and the stepped shaft length are changed to check its effects on the natural frequencies. the results showed that the natural frequencies increase with an increase in the amount and length of the stepped part, while they decrease the closer the disc position to the center.

Coaxiality of Stepped Shaft Measurement Using the Structured Light Vision

A method is proposed to measure the coaxiality of stepped shafts based on line structured light vision. In order to solve the repeated positioning error of the measured shaft, the light plane equation solution method is proposed using movement distance and initial light plane equation. In the coaxiality measurement model, the equation of the reference axis is obtained by the overall least square method through the center point coordinates of each intercept line on the reference axis. The coaxiality error of each shaft segment relative to the reference axis is solved based on the principle of minimum containment. In the experiment, the coaxiality measurement method is evaluated, and the factors that affect the measurement accuracy are analyzed.

Hot and cold flashless forging in vertical split dies of a stepped shaft

Flashless forging is classified as a precise metal forming technology. The main advantages of this technology are the reduction of the flash allowance and the shortening of the manufacturing time by eliminating the flash trimming operation. The article presents the process of one-step forging of a stepped shaft made of aluminum with the use of split dies. The process was carried out in cold and hot metal forming conditions. The forging process was analyzed numerically using the Simufact.Forming 15.0 software. The geometrical parameters of the obtained product were analyzed, the distribution of effective strain, temperature and the standardized cracking criterion were determined. The process force parameters were also determined. Numerical tests were verified in real conditions with the use of a specially designed device for forging in vertical split dies. Comparison of hot and cold forging in vertical split dies is presented.

A Rotary Compression Process for Producing Hollow Gear Shafts

This paper presents selected numerical and experimental results of a study investigating the process of forming hollow stepped gear shafts from tubes by rotary compression. The objective of the study was to determine whether the rotary compression process is an effective method of producing hollow stepped gear shafts and to identify limitations of this manufacturing method. A theoretical analysis involved the numerical modeling of the proposed process by the finite element method (FEM). 3D simulations were performed using the commercial simulation software package Simufact Forming. The analysis involved examining the material flow pattern along with thermal and force parameters of the process. The FEM results were verified with experimental tests conducted under laboratory conditions. The experiments were performed on a machine specially designed for the rotary compression of hollow parts. Results demonstrate that it is difficult to form a stepped gear shaft in one operation. For this reason, such parts should be formed in two operations. The first operation involves the forming of a hollow stepped shaft by rotary compression, while in the second operation, a gear is formed on one of the steps of the shaft.