TY - JOUR

T1 - Modeling of spray cooling during induction hardening of spur gearwheels made from 42CrMo4 hardening and tempering steel

AU - Rodman, Dmytro

AU - Boiarkin, Viacheslav

AU - Nürnberger, Florian

AU - Dalinger, Andrej

AU - Schaper, Mirko

PY - 2014/5

Y1 - 2014/5

N2 - The application of water-air spray cooling in the process of induction surface hardening according to the simultaneous dual-frequency technology represents a hitherto unexploited and equivalent alternative to conventionally employed polymer solutions. The reason for this is that the selection of the optimum parameters is associated with a high experimental outlay and analytical effort for performing the tests and evaluating the results, respectively, and the parameters must be selected for a specific application. In order to reduce this effort, a numerical model was developed to formulate the coupled thermal, microstructural, and mechanical processes during quenching by means of water-air spray cooling of induction heated spur gearwheels made from 42CrMo4 hardening and tempering steel. The model was implemented in the commercial simulation software ANSYS Workbench 13.0 and verified using simulation results for temperature development, hardness distribution, residual stresses, and distortion. A comparison of the simulated and experimental results show that the model introduced here is suitable for predicting the hardening results during quenching using spray cooling subsequent to induction heating. Volume fraction of martensite in the tooth during quenching using 0.3 MPa air and 0.3 MPa water pressures after 2 s (a), 2.2 s (b) and 2.4 s (c). A numerical model was introduced describing the quenching process using spray cooling subsequent to induction heating. The model serves to predict the temperature development and the hardening results in the form of microstructural and hardness distributions, residual stresses, and distortion.

AB - The application of water-air spray cooling in the process of induction surface hardening according to the simultaneous dual-frequency technology represents a hitherto unexploited and equivalent alternative to conventionally employed polymer solutions. The reason for this is that the selection of the optimum parameters is associated with a high experimental outlay and analytical effort for performing the tests and evaluating the results, respectively, and the parameters must be selected for a specific application. In order to reduce this effort, a numerical model was developed to formulate the coupled thermal, microstructural, and mechanical processes during quenching by means of water-air spray cooling of induction heated spur gearwheels made from 42CrMo4 hardening and tempering steel. The model was implemented in the commercial simulation software ANSYS Workbench 13.0 and verified using simulation results for temperature development, hardness distribution, residual stresses, and distortion. A comparison of the simulated and experimental results show that the model introduced here is suitable for predicting the hardening results during quenching using spray cooling subsequent to induction heating. Volume fraction of martensite in the tooth during quenching using 0.3 MPa air and 0.3 MPa water pressures after 2 s (a), 2.2 s (b) and 2.4 s (c). A numerical model was introduced describing the quenching process using spray cooling subsequent to induction heating. The model serves to predict the temperature development and the hardening results in the form of microstructural and hardness distributions, residual stresses, and distortion.

KW - induction hardening

KW - numerical modeling

KW - spray cooling

KW - verification

UR - http://www.scopus.com/inward/record.url?scp=84899843925&partnerID=8YFLogxK

U2 - 10.1002/srin.201300201

DO - 10.1002/srin.201300201

M3 - Article

AN - SCOPUS:84899843925

VL - 85

SP - 741

EP - 755

JO - Steel research international

JF - Steel research international

SN - 1611-3683

IS - 5

ER -