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MODELING OF INDUCTION HARDENING PROCESS PART 1: INDUCTION HEATING. Dr. Jiankun Yuan Prof. Yiming (Kevin) Rong. Acknowledgement: This project is partially supported by Delphi and CHTE at WPI. Dr. Q. Lu was involved in the early work of the project. http://me.wpi.edu/~camlab.
Dr. Jiankun Yuan
Prof. Yiming (Kevin) Rong
Acknowledgement: This project is partially supported by Delphi and CHTE at WPI. Dr. Q. Lu was involved in the early work of the project.
Greatly shortened heat treatment cycle
Highly energy efficiency
Research content:FEM based electromagnetic/thermal analysis
+ quenching analysis + hardening analysis
Numerical modeling may provide better prediction
Research objective: (1)ProvideT field, time history inside WP
(2) Determine formed content of martensite, pearlite and bainite.
(3) Determine hardness distribution in WP.
(4) Guidance for induction system design.
Joule heat by
High freq. AC power
(a) WP geometry
(c) Interior element
(d) Surface elementPrinciple: Electromagnetic and Thermal Analysis
Thermal Analysis with finite element model
Input AC power to coil
magnetic vector potential (A)
magnetic flux density (B)
B = A
(Gauss’ Law for
magnetic field intensity (H)
H = B /
electric field intensity (E)
electric field density (D)
D = E
current density (J)
(Ampere’s Circuital Law)
Inducting heat (Qinduction)
Qinduction = E J = J2/
Heat generation Qinduction in WP
Induced Joule heat
Material: Carbon Steel, AISI 1070
Automotive parts from Delphi Inc., Sandusky,Ohio
Real spindle to be hardened
Mesh generated by ANSYS
FEA model and B.C.
(a) Electromagnetic Properties
(b) Thermal Properties
(a1) Constant current distribution in coil (a2) heated pattern
(b1) Adjusted current distribution in coil (b2) heated pattern
Total heating time th = 7.05s
f=9600Hz s=1.27mm J=1.256e6 A/m2
• A finite element method based modeling system is developed to analyze the coupled electromagnetic/thermal process in induction heating andimplemented in ANSYS package, with following capabilities.
• Provide electrical and magnetic field strength distribution.
• Provide instantaneous temperature field data in workpiece.
• Provide Temperature history at any location in heating process.
• Provide guidance for inductor/coil design based on adjustment of current density distribution and desired heating patterns.