A New Approach in Optimizing the Induction Heating Process Using Flux Concentrators: Application to 4340 Steel Spur Gear

• Published in: Journal of materials engineering and performance Vol. 23; no. 9; pp. 3092 - 3099
• Main Authors: Barka, Noureddine, Chebak, Ahmed, El Ouafi, Abderrazak, Jahazi, Mohammad, Menou, Abdellah
• Format: Journal Article
• Language: English
• Published: Boston Springer US 01-09-2014; Springer
• Subjects: Applied sciences; Characterization and Evaluation of Materials; Chemistry and Materials Science; Corrosion and Coatings; Engineering Design; Exact sciences and technology; Heat treatment; Materials Science; Metals. Metallurgy; Production techniques; Quality Control; Reliability; Safety and Risk; Tribology; 3D model; spur gear; induction heating; high frequency and medium frequency; Temperature distribution; High strength steel; Hardness; Optimization; Induction heating; Heat transfer equation; Finite element method; Three dimensional model; Edge effect; Electromagnetic field; Spur gear; Maxwell equation
• ISSN: 1059-9495; 1544-1024
• DOI: 10.1007/s11665-014-1088-3

The beneficial effects of using flux concentrators during induction heat treatment process of spur gears made of 4340 high strength steel is demonstrated using 3D finite element model. The model is developed by coupling electromagnetic field and heat transfer equations and simulated by using Comsol software. Based on an adequate formulation and taking into account material properties and process parameters, the model allows calculating temperature distribution in the gear tooth. A new approach is proposed to reduce the electromagnetic edge effect in the gear teeth which allows achieving optimum hardness profile after induction heat treatment. In the proposed method, the principal gear is positioned in sandwich between two other gears having the same geometry that act as flux concentrators. The gap between the gear and the flux concentrators was optimized by studying temperature variation between the tip and root regions of gear teeth. Using the proposed model, it was possible identifying processing conditions that allow for quasi-uniform final temperature profile in the medium and high frequency conditions during induction hardening of spur gears.