Simulation of multi-frequency-induction-hardening including phase transitions and mechanical effects

Induction hardening is a well known method for the heat treatment of steel components. With the concept of multi-frequency hardening, where currents with two different frequency components are provided on a single inductor coil, it is possible to optimize the hardening zone to follow a given contour even in the case of complicated 3D geometries like gears.In this paper, we consider the simulation of multi-frequency induction hardening in 3D. The equations to solve are the magneto-quasistatic approximation of Maxwell's equations describing the electromagnetic fields, the balance of momentum to determine internal stresses and deformations arising from thermoelasticity and transformation induced plasticity (TRIP), a rate law to determine the distribution of different phases and the heat equation to determine the temperature distribution in the workpiece.The equations are solved using adaptive finite element methods. The simulation results are compared to experiments for discs and for gears. A very good agreement for the hardening profile and the temperature is observed. It is also possible to predict the distribution of residual stresses after the heat treatment. HighlightsIntroduction of a multi-physics model for multifrequency induction hardening in 3D.An efficient FEM simulation using edge elements and adaptivity is presented.Simulation results show a very good correspondence between experiment and simulation.Prediction of hardening profile and stress distribution after heat treatment.

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