Coupled Multi-physics Modeling of Induction Gear Hardening Processing Methods

Induction hardening is a popular heat treatment method for producing gears with wear and fatigue resistant teeth. Its popularity is due to its advantages versus carburizing heat treatment: faster production speed, fewer process requirements, less environmental impact and better hardening control.

The modeling of induction hardening is not uncommon, though many efforts rely on results from dissimilar simulation systems. Capable simulation systems couple complex multi-physics (thermal, mechanical, electrical, magnetic) within a single environment. This allows for integration with multiple-operation, DOE/optimization and ICME modeling tools.

Various gear spin hardening methods were studied in the DEFORM^® system to demonstrate how process selection affects induction heat treatment behavior. Single and dual frequency induction hardening processes were evaluated with different frequency, power and time schedules. Through and contour hardened teeth were produced on a variety of gear shapes. Simulation results revealed the electro-magnetic, thermo-mechanical and phase transformation kinetics that determined final tooth hardening patterns.