integrated computational development of induction heat ... · induction heat treatment process for...
TRANSCRIPT
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IntegratedComputationalDevelopmentofInductionHeatTreatmentProcessfor
AutomotiveAxleShafts
RobertGoldstein(1),Dr.ValentinNemkov(1),Dr.LynnFerguson(1),Dr.ZhichaoLi(1)
(1)Fluxtrol,Inc.,AuburnHills,MI,USA
(2)DANTESOFTWARE,Cleveland,OH,USA
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• Inductionhardeninginvolvesmultiplephenomena,including:electromagnetic,thermal,metallurgical,stressanddeformation
• Stateoftheartmethodisdevelopedtocouplethesephysicstogether
• Fluxsoftware(electromagneticandthermalcapabilities)iscoupledwithDANTE(thermal,stress,distortionandappliedloadcapabilities)
• Casechosenforstudyisafull-floataxle,dimensionstypicalforaxlesmanufacturedandhardenedbyinductionheating
Introduction
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Mutuallycoupledphenomenaininductionheatingprocess
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Failure
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AxleDimensionsUsedinModel
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Axles can be broken into 3 main regions: Radius and Flange, Shaft, and Spline
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2-TurnCoilDesign
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Example of fully assembled axle coil Flux 2D model showing mesh (left) and temperature (right) at end of dwell
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DuetoSymmetry,SingleToothofSplineisModeledinDANTE
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Finite element meshing in DANTE is displayed
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PowerDensityin3Regions(Flux2D)
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Power densities are extracted from Flux 2D and imported to DANTE
Radius Shaft Spline
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TemperatureValidationBetweenFluxandDANTE
8
Flux 2D DANTE
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DANTESimulationofScanningProcess
9
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StressesandDimensionalMovementafterHardening
10
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EffectofTemperingonResidualStresses
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SimulationofTorsionalLoads
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DanteSimulationofTorsionalLoads
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FailurePrediction
(Left) Fatigue crack, and (Right) Overload crack. Courtesy of Dana Corp.
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• ElectromagneticmodelingbyFluxandthermal-stressmodelingbyDANTEweresuccessfullycoupled
• Highsurfacecompressionandhightensilestressesincorewerepredictedinmodel
• Thelargesttensilestressesoccuratthebaseoftheshaftandatthespline
• Totalaxialgrowthis2.3mmandradialshrinkageinshaftis4μm.Theauthorshaveshownotherpapersthattheaxialgrowthandstressprofilesarestronglyinfluencedbythequenchingseverity.
• VirtualLoadswereappliedtotheaxlethatsimulatetorsionaltestingequipmentusedinindustry.Failuremodepredictionsaresimilartowhathasbeenfoundwhiletestingrealcomponents,showingthattheresidualstressesfromtheheattreatingprocesshaveastronginfluenceonthecomponentperformance.
• Additionalworkneedstobedonetoincorporateresidualstressesfrommanufacturingoperationspriortotheinductionheattreatingprocesstoimprovetheaccuracyofthepredictions.
Conclusions
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