induction hardening - 齿轮 感应淬火

eldec Induction USA Inc
Company History
1982 Formation of eldec Schwenk Induktorbau GmbH by Wolfgang Schwenk. Vision for application and development of Induction technology and coil design. 1993 Delivery of the first eldec-designed IGBT high frequency and medium frequency generators. 1998 eldec Induction USA was founded. 2000 Delivery of the first Dual Frequency SDF® generators. 2004 Delivery of the first 1-MW SDF® hardening system. 2006 Completion of the first 3-MW SDF® hardening system. 2008 Modular Induction (MIND) Hardening Machine introduced at AMB Stuttgart. 2009 The SDF®-Technology is gaining further market share. eldec establishes Sales and Service facility in China.
eldec Induction USA Inc.
MAINSTREAMING THE PROCESS CHAIN:
IN-LINE HARDENING FOR TIME AND MONEY
eldec Induction USA Inc.
MAINSTREAMING THE PROCESS CHAIN:
IN-LINE HARDENING SAVING TIME AND MONEY
eldec Induction USA Inc.
2.
What is Contour True Hardening? Process Comparison
Carburization True contour 1. Carburizing the case above Ac3 in oven Induction Single Frequency Non-true contour 1. Single frequency coil induces eddy current in workpiece 2. Quench to harden with fluids 3. Temper to achieve case depth hardness based on mechanical properties required. Quenched and tempered steels with C > 0.35%, example 1040 or 4140 (42CrMo4) Induction Simultanious Dual Frequency SDF® True contour 1. Simultaneous dual frequency coil induces eddy current in workpiece 2. Quench to harden with fluids 3. Temper to achieve case depth hardness based on mechanical properties required. Quenched and tempered steels with C > 0.35%, example 1040 or 4140 (42CrMo4)
eldec Induction USA Inc.
Medium frequency only
A = MF- inductor current B = Eddy current C = Heat mainly in root of gear tooth
With medium frequency the root area of the teeth will be heated rather then the tip of the teeth. The inductive current is canceling out in the flange area, due to the lower frequencies (D too small for lower frequencies).
Pull
Inner Stress distribution
Push
after heat treatment RED - ResidualStress distribution diagram
Tensile Stress distribution diagram (by outside forces)
eldec Induction USA Inc.
2.
What is Contour True Hardening? Comparison of Additional Process Considerations
Process Carburization TRUE CONTOUR Induction Single Frequency NON TRUE CONTOUR Induction Simultanious Dual Frequency SDF® TRUE CONTOUR
Process
WEAR RESISTANT CASE PART DISTORTION DUCTILE CORE STRUCTURE TENSILE STRENGTH
++ HIGH +
CORE HARDNESS ACHIEVED IN PROCESS
++ MEDIUM +
++ LOW + +
+
Thru Hard teeth
Data not available
Hardening With Single Frequency Hardening With Dual Frequency eldec SDF® Total Power: 450 kW HF Total Power: 820 kW HF + MF Heat Time: 12 sec pulsed Heat Time: 0.32 sec Energy Used: ≈ 3000 kWs Energy Used: ≈ 290 kWs
Suitable Materials
Sectioned Parts:
eldec Induction USA Inc.
2.
What is Contour True Hardening? Comparison of Workpiece Mechanical Properties
Carburization TRUE CONTOUR Induction Single Frequency NON TRUE CONTOUR Induction Simultanious Dual Frequency SDF® TRUE CONTOUR
In-Line Induction Hardening
eldec Induction USA Inc.
4.
Workpiece and Manufacturing modifications to incorporate Hardening into the process chain SUITABLE MATERIAL: C > 0.35% SUITABLE WORKPIECE AND LOT SIZE SHORT PROCESS TIME = HIGH POWER DENSITY
eldec Induction USA Inc.
Agenda:
1. 2. 3. Introduction of eldec What is Contour True Hardening? Why bother with Hardening as an integral part of the process chain? 4. Workpiece and Manufacturing modifications to incorporate Hardening into the process chain 5. 6. 7. 8. The eldec SDF® process Case studies Products and Systems Q&A
eldec Induction USA Inc.
The broad range generator program consists of medium frequency and high frequency generators starting at 1.5 kW to 500kW as well as the SDF®-Generators starting at 15 to 3000 kW.
Line with remote carburizing ovens
HIGH PROCESS CAPABILITY (SPC). REPEATABLE ENERGY. PRECISE TOOLING RE-THINK -
In-Line Induction Hardening
HARDENING AS A PART OF MANUFACTURING, NOT METALLURGY
PROCESS CAPABILITY (SPC) FLEXIBILITY ENVIRONMENTAL IMPACT ENERGY EFFICIENCY
NEUTRAL HIGH HIGH LOW
POSITIVE MEDIUM LOW MEDIUM
POSITIVE PLUS HIGH VERY LOW HIGH
elБайду номын сангаасec Induction USA Inc.
3.
Why bother with Hardening as an integral part of the process chain?
■ TO LOWER COST
Line with remote carburizing ovens
■ TO SAVE TIME ■ TO SAVE ENERGY
Process
Process Principals
2. Quench to harden with fluids or gases 3. Temper to achieve case depth hardness based on mechanical properties required. Quenched and tempered carburized steels with C < 0.25%, example 5115 (16MnCr5)
eldec Induction USA Inc.
2.
What is Contour True Hardening? Comparison of Process Characteristics
Process Carburization TRUE CONTOUR Induction Single Frequency NON TRUE CONTOUR Induction Simultanious Dual Frequency SDF® TRUE CONTOUR
eldec Induction USA Inc.
Most common industries for eldec induction heat treatment technologies: Electro-technical Industry Automotive Machines and Systems Tool and Die Industry Aerospace Power Generation
TOTAL PROCESS TIME FEASIBILITY OF SINGLE-PIECE PART FLOW
MULTIPLE HOURS ++
30 – 60 SEC.
< 30 SEC.
VERY LOW
MEDIUM
HIGH
++ Rule of thumb for carburizing is 1 hr per 0.1 mm carb depth (eg., 1.5 mm depth in 15 hours at 1 atmosphere)