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Induction heating is a case hardening process used to improve performance of machine components by producing a hard martensitic microstructure and high compressive residual stresses at the surface layer. A reliable numerical model able to predict the hardness profile would shorten process development. However, the accuracy and the efficiency of the model are restricted by the coupling complexity between the electromagnetic and thermal fields, and the nonlinear behaviour of the material properties. The paper analyzes the sensitivity of the material properties values and of the finite element meshing onto the predictive modeling of the case hardening profiles. The material used is SAE-4340 low-alloy steel. The simulations are done using a computer-modeling software (Comsol) and the sensitivity analysis is conducted by using an experimental design method.

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The application of the three-dimensional finite-element substructure method has helped to improve the accuracy of calculation of gear tooth contact and fillet stresses in large spur and helical gear systems. The development of a dedicated preprocessor has reduced significantly the manual effort involved in the analysis. The methodology is explained using the example analyses of the gear systems in the two stages of a typical speed reduction gearbox used in the Pratt & Whitnev-Canada PVV100 turbopropeUer engines. n p(x) Nomenclature A l9 A 2 ,A 3= constants in the expression for the line load intensity B^B 2 ,B 3 ,B 4 = constants in the expression for normal displacement L = length of line of contact on the tooth contact face = number of nodes along a contact line = line load intensity as a function of distance = reactive force at node / = distance along line of contact on the tooth contact face -normal displacement at node i = normal displacement distribution as a function of x