Multi-variant calculations of induction heating process

Purpose: Induction heating process is often used as the first stage of quenching process. Computer simulation of the induction heating make it possible to eliminate expensive and time-consuming experimental selection of parameters. The selection of appropriate heating parameters is particularly difficult for the irregularly shaped parts. Gears are an example of such elements. In the case of surface quenching / heating a uniform distribution of temperature field is necessary on the surface and expected temperature gradient inside the heated gear. The following parameters: inductor frequency, inductor power, heating time, inductor geometry, distance between inductor and heating gear and relative shift between inductor and gear have a significant effect on the temperature distribution. Obtaining the correct temperature distribution requires proper selection of the above mentioned parameters. Numerical optimization or multi-variant calculations are the best way to achieve the goal.Design/methodology/approach: This work presents numerical simulation of induction heating. Such simulation consists of an analysis of coupled electromagnetic and thermal fields. Commercial program Flux 3D, was used to perform the calculations.Findings: Execution of 10 variants of calculation enables to obtain the optimal values of the parameters influencing the heating process.Practical implications: During the test quenching of the gear a problem of non uniform temperature distribution appears. The attempts of experimental selection of heating parameters failed, and the problem was solved by multi-variant calculations. The results obtained from the calculations were successfully applied in the quenching process.Originality/value: This paper shows an application of numerical simulation in gear quenching. The results of simulations were practically verified.