Radio Frequency Division

Technology

Heat Treating Simulation

Simulation of Induction Heating for estimation of product quality after heat treatment

  • We at DKK Co., Ltd. offer simulation of high frequency induction heating to help estimate product quality after heat treatment.
  • The simulation is available using FEM (Finite Element Method)-based coupled analysis of magnetic field and heat conduction with the magnetic field analysis software.
  • Estimation of heating temperature profile is attained by creating the work and coil models with 3D CAD or other proper tools and freely selecting various parameters for heating conditions such as frequency, heating power and heating time.
  • For three-dimensional (3D) analysis problems, calculated solutions may be obtained by giving rotational motion to the heat generated in the work or work ins.

<Example Analysis>
Analysis of hub inner shaft based on 3D model

 

Heating coil used for verification  Work (Image)
Photo: Heating coil used for verification  Figure: Work (Image)

 

Analysis Conditions FEM model
 Total number of elements:
       675,571 (Electromagnetic field)
       461,114 (Thermal field)
 Coil electric current: 3,666〜3,750A
      (Based on measurement values)
 Heating time: 5.7sec
 Frequency: 30kHz
Figure: FEM model

 

Schematic representation of changing temperature distributions over the work with heating time is shown below. It helps estimate the heating time until the heat reaches the intended depth of quench-hardened case.

 

Figure: after heat start1.5sec
after heat start1.5sec
Figure: after heat start3.0sec
after heat start3.0sec
Figure: after heat start4.5sec
after heat start4.5sec
Figure: after heat start5.7sec
after heat start5.7sec
Figure: Temperature distributions

 

Analysis of internal quenching of the hub outer ring

 

Coil and work (image)
Figure: Coil and work (image)
 Frequency: 30kHz
 Heating time: 4.0sec

 

Changing temperature distributions across the workpiece cross section with heating time is shown below.
Figure: Temperature distributions (Cross section)
Temperatures at the corners are found rising first followed by increasing temperatures in the major diameter sections.

 

Distortion analysis in the R quenching of a crankshaft

 

By expanding the heat dissipation data from the 2D magnetic field analysis to 3D, tendency of distortions in the crankshaft with multiple positions to be quenched may be anticipated.
Distortion analysis for a 4-cylinder crankshaft is shown below. Five (5) journals and 4 pins will be hardened.

 

Figure: Part of hardening

 

 

Estimated distortion profile at the end of quenching is shown below (distortion level scaled up 100 times). The third journal is found distorted convex downwards.

 

Figure: Distortion of hardening (Distortion is multiplied 100 times.)

 

We at DKK Co., Ltd. aim to consistently offer optimum coil designs and quenching conditions for your precise application needs using analysis software.

 

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TEL.+81-3-3216-1682
FAX.+81-3-3216-1669

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