Analysis of Errors in Simulation Modeling

Computer based simulation programs for induction heating and resulting metallurgy are extremely useful in developing tooling and process for induction heating. Induction hardening simulation brings elements of inductor design, steel properties such as time-temperature-transformation curves, both thermal and magnetic properties at various temperatures and cooling rate based on the phase of the quench media on cooling.

A common method in place hardening (static hardening) known as single shot hardening. In this process, the inductor is designed with a top and bottom half loop connected by heating rails. The length of heating is determined by the length of the rails and a percentage height of the width of the half loops. Accurately predicting the length of the heating pattern in this 3D modeling approach is computationally a heavy load on the modeling pre-requisites. Commonly the inductor is modeled and then tested with the actual results showing a different length than what was predicted.

This paper reaches into the analysis of why the predicted length may differ from the test results discussing what factors constitute the largest variance from the predicted outcome. Errors in computational ability of the software, material specification, Inductor design and the reliance on set up will be discussed.