Simulation of induction hardening: Simulative sensitivity analysis with respect to material parameters and the surface layer state

Mühl, Fabian; Damon, James; Dietrich, Stefan; Schulze, Volker

doi:10.1016/j.commatsci.2020.109916

Cited by 17 publications

(4 citation statements)

References 13 publications

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“…Residual stress is an important factor affecting the fatigue life of parts. Areitioaurtena et al [15,16] have discussed the effect of induction hardening residual stresses on rolling contact fatigue lifetime and confirmed that a life extension up to 156% can be achieved with compressive residual stresses. Y. Hu [17] and J. W. Gao [18] studied the effect of induction quenching on the fatigue life, and showed that the remaining life of a damaged part with residual compressive stress is more than three times that of a part without residual compressive stress.…”

Section: Introductionmentioning

confidence: 92%

Effect of Different Microstructures on Surface Residual Stress of Induction-Hardened Bearing Steel

Lu,

Chiu

2024

Metals

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JIS SUJ2 steel is most widely used in bearing steel. The advantages are good hardenability, excellent fatigue, wear resistance and comprehensive mechanical properties. The wear resistance and fatigue resistance of this steel are attracting more attention, and the residual stress state and its distribution on the surface of the heat affected zone are critical factors affecting the fatigue life and wear resistance of the parts. In this study, SUJ2 is used as a material by which to study the surface residual stress and retained austenite distribution of induction-hardened steel. Quenching and tempering treatments were used to obtain different microstructures and an induction method was used to re-quench the case region. After the heat treatment, the residual stress and retained austenite volume on the surface were analyzed by X-ray diffraction and analyses of the microstructure and the hardness were also conducted. The results show that the microstructure after heat treatment contains unsolved carbides, tempered martensite and retained austenite. In the induction-hardened area, the residual stress is all compressive, and the values are more than −750 MPa. In conclusion, the microstructures of the specimens before induction hardening have a significant impact on the effective case depth for the same output power condition and the surface residual stress changes from a tensile to a compressive state. In the induction-hardened area, the maximum of the residual compressive stress was increased as the austenitized temperature of quenching increased.

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Section: Introductionmentioning

confidence: 92%

Effect of Different Microstructures on Surface Residual Stress of Induction-Hardened Bearing Steel

Lu,

Chiu

2024

Metals

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“…A finite element analysis (FEA) program is then used to evaluate the design requirements of each topology. If the design requirements are not met, the following options are available: Adjust the parameters within the acceptable range for the selected topology [ 47 ]. If the parameter search space for the specified topology has been fully explored, change the structural topology and repeat the process (the topology is discarded after 20 iterations if the design requirements are still unsatisfied).…”

Section: Topology Design Of Torsion Springmentioning

confidence: 99%

Design and Characterization of a Low-Cost and Efficient Torsional Spring for ES-RSEA

Al-Dahiree

Ghazilla

Tokhi

et al. 2023

Sensors

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The design of torsional springs for series elastic actuators (SEAs) is challenging, especially when balancing good stiffness characteristics and efficient torque robustness. This study focuses on the design of a lightweight, low-cost, and compact torsional spring for use in the energy storage-rotary series elastic actuator (ES-RSEA) of a lumbar support exoskeleton. The exoskeleton is used as an assistive device to prevent lower back injuries. The torsion spring was designed following design for manufacturability (DFM) principles, focusing on minimal space and weight. The design process involved determining the potential topology and optimizing the selected topology parameters through the finite element method (FEM) to reduce equivalent stress. The prototype was made using a waterjet cutting process with a low-cost material (AISI-4140-alloy) and tested using a custom-made test rig. The results showed that the torsion spring had a linear torque-displacement relationship with 99% linearity, and the deviation between FEM simulation and experimental measurements was less than 2%. The torsion spring has a maximum torque capacity of 45.7 Nm and a 440 Nm/rad stiffness. The proposed torsion spring is a promising option for lumbar support exoskeletons and similar applications requiring low stiffness, low weight-to-torque ratio, and cost-effectiveness.

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“…A more efficient method for guiding and optimizing processes is the use of numerical techniques, such as finite element modeling (FEM), which has proven to be relevant in dealing with multiphysics-based parametrized problems [36]. As a result, many studies have focused on using FEM to analyze hardness with relevant accuracy [37][38][39][40][41][42][43]. However, this approach is restricted by the computational cost.…”

Section: Introductionmentioning

confidence: 99%

Data-Driven Inverse Problem for Optimizing the Induction Hardening Process of C45 Spur-Gear

Garois

Daoud

Chinesta

2023

Metals

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Inverse problems can be challenging and interesting to study in the context of metallurgical processes. This work aims to carry out a method for inverse modeling for simultaneous double-frequency induction hardening process. In this investigation, the experimental measured hardness profiles were considered as input data, while the output data were the process parameters. For this purpose experiments were carried out on C45 steel spur-gear. The method is based on machine learning algorithms and data treatment for dealing with inverse approach issues. In addition to the inverse modeling, a forward problem-based verification completes the study. It was found that according to promising results that this method is suitable and applicable for inverse problem of hardness modeling.

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Simulation of induction hardening: Simulative sensitivity analysis with respect to material parameters and the surface layer state

Cited by 17 publications

References 13 publications

Effect of Different Microstructures on Surface Residual Stress of Induction-Hardened Bearing Steel

Effect of Different Microstructures on Surface Residual Stress of Induction-Hardened Bearing Steel

Design and Characterization of a Low-Cost and Efficient Torsional Spring for ES-RSEA

Data-Driven Inverse Problem for Optimizing the Induction Hardening Process of C45 Spur-Gear

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