Induction hardening is an important heat treatment operation for a number of components, including shafts, crank-shafts, gears, and axles to improve wear and fatigue properties. These parts are widely used in automotive as well as off-highway vehicles. Induction hardening process comprises of two distinct steps, induction heating and quenching operation. It involves phenomenologically many overlapping complex processes such as temperature evolution, phase transformation, microstructure evolution and structural changes. Therefore, it is important to understand and quantify the aforementioned processes to avoid the residual stress and distortion in the component resulting from induction hardening. In the present work, a two step simulation methodology has been developed by coupling two commercial FEA softwares, based on electromagnetic and heat treatment simulations, respectively. This methodology enables accurate prediction of the temperature profile in the component during induction heating as well as the changes in temperature, phase transformation, microstructure, residual stress and distortion during the subsequent quenching step. In the present work, the coupled simulation exercise was carried out on a simple geometry (solid cylinder) as well as a complex geometry (ring gear). Thus, the obtained simulation results were validated with the experimental data and found to be in good agreement. The present study shows that an integrated methodology of solving induction hardening gives an opportunity to include large number of process information and providing precise prediction and thereby enables opportunity for process and design optimization.
This presentation would detail on the overall approach, validation results and optimization possibility.