Transfer project T-B5: Processdevelopment of inductive dual frequence surface hardening by numerical modeling

Person in Charge: Dipl.-Ing. Bernhard Kaufmann

Motivation and aims:
Today inductive dual frequency surface hardening is an innovative, established heat treatment process. Nevertheless, the development of this complex process for industrial application is associated by a huge number of experiments. Numerical models are used to get a better knowledge of the process in itself and to shorten and optimize the development procedure. The aim of transfer project T-B5 is to improve the numerical model, which has been implemented in project B5, with regard to the material- and process model and the utilization in the context of industrial process development at the transfer partner Robert Bosch GmbH.

Investigations

First Results

Numerical Model of dual frequency induction hardening with finite elements
Implementation of a material model describing the material behavior (based on results of project B5)
Thermal analysis with a dilatometer and a short time austenitization test engine
Induction hardening of gears (42CrMo4) at the transfer partner Robert Bosch GmbH
Characterization of material state at the surface by optical analysis of the microstructure, measurement of eigenstresses and micro hardness
ecological and economic balance of dual frequency surface hardening

Implementation in ABAQUS 6.11
Transfer of the existing material model for 2D-simulation into 3D-simulation
First steps towards a 3D numerical model of the induction heat treatment of gears

Induction hardening of gears
First characterization of the material state in the surface of the hardened gears