Multi response Optimization of Induction Hardening Process -a New Approach

Abstract In this present paper, an investigation has been performed to find out the combination of input process parameters for induction hardening of AISI 1045 steel component based on desirability function. To enhance the mechanical properties of steel components using induction hardening process, quality responses like effective case depth (ECD) and hardness values are analysed for different combinations of medium frequency power, feed rate, quench pressure and temperature in a selected range. The experimental trials are conducted, based on the design matrix obtained from the rotatable central composite design (CCD), with the help of an induction hardening station equipped with a 150 kW power converter. A significant regression model is also developed to predict these quality responses using response surface methodology (RSM). To establish desirability index in a multi-response process like induction hardening, a new approach has been devised. This approach i.e. selection of both, heating and quenching parameters proved significant, which is considered as one of the major contribution of presented research work. A non destructive evaluation technique, based on dynamic response, is also developed which will further combine with optimization strategy to develop an innovative quality assurance system for industrial induction hardening process.

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