Depending upon the gear size, required hardness pattern, and tooth geometry, gears are induction hardened by encircling the whole gear with a coil (so-called “spin hardening of gears”), or for larger gears, heating them tooth-by-tooth. This paper focuses on recent inventions • Simultaneous dual-frequency induction • IFP technology for induction gear and innovations (from the past four-six hardening hardening years) in induction hardening of gears and • Advanced induction-hardening process • Induction tempering and stress relieving gear-like components, including, but not recipes when hardening small and of gear-like components with improved limited to: medium size gears temperature uniformity • N ovel inductor designs to minimize • “Know-how” in controlling distortion distortion when induction hardening This paper also provides a review of of induction-hardened gears hypoid and spiral bevel gears basic principles and applications devoted
Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the AMERICAN GEAR MANUFACTURERS ASSOCIATION.
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Figure 2: Induction gear hardening machine for a large bearing ring with teeth located on outside (Courtesy of Inductoheat Inc.)
pitch gears (modules smaller than 6) [1,2]. the tooth, leaving the tip and tooth core soft, Figure 1 (left): In tooth-by-tooth hardening, During “tip-by-tip” hardening, an inductor tough, and ductile (Figure 1). Though this inductors can be designed to selectively harden encircles a body of single tooth. Presently, this is one of the oldest hardening techniques, specific areas of gear teeth where metallurgical changes are required [2] technique is not used because the hardening recent innovations continue improving quality patterns typically do not provide the required of gears heat-treated using this method. to induction hardening small, medium, fatigue and impact strength. “Gap-by- Thermal expansion of metal during the and large gears using tooth-by-tooth gap” hardening is a much more popular heating should be taken into consideration techniques and encircling method. technique compared to “tip-by-tip” method. when determining and maintaining the proper Depending upon the gear size, required This is the reason why the term “tooth-by- inductor-to-tooth air gap. After gear loading hardness pattern, and tooth geometry, tooth” hardening is often associated with the and initial inductor positioning, the process gears are induction hardened by encircling “gap-by-gap” hardening method. “Gap-by- runs automatically, based on an application the whole gear with a coil (so-called “spin gap” hardening requires the inductor to be recipe. Figure 2 shows examples of induction hardening of gears”), or for larger gears, symmetrically located between two flanks of using a tooth-by-tooth hardening machine. heating them tooth-by-tooth [1-6]. adjacent teeth. Inductor geometry depends When developing tooth-by-tooth gear upon the shape of the teeth and the required hardening process, particular attention “Tooth-by-tooth” Hardening hardness pattern. Special locators (probes) should be paid to electromagnetic end/ The tooth-by-tooth method comprises two or electronic tracing systems are often used edge effects and the ability to provide the alternative techniques: “Tip-by-tip” or “gap- to ensure proper inductor positioning in the required pattern in the gear end areas. Upon by gap” hardening [1-4]. The “tip-by-tip” tooth space. scanning gear tooth, the temperature is method can apply a single-shot heating Two scanning techniques used include one distributed within gear roots and flanks quite mode or scanning mode; the “gap-by- in which the inductor is stationary and the gear uniformly. At the same time, since the gap” technique applies the scanning mode is moveable, and the other in which the gear eddy current makes a return path through exclusively. Inductor scanning rates are is stationary and the inductor is moveable. the flank and, particularly through the typically within 6 mm/sec to 9 mm/sec. Both The latter technique is more popular when tooth tip, proper care should be taken to “tip-by-tip” and “gap-by-gap” techniques are hardening large gears. Inductors can be prevent overheating the tooth tip regions, typically not very suitable for small and fine- designed to heat only the root and/or flank of particularly at the beginning and end of
thermalprocessing.com | 29 Figure 6: TSH Technology uninterrupted induction hardened pattern is obtained on a spiral bevel gear. (Courtesy of ERS Engineering Corp.)
the scan hardening. Improved system design helps to maintain
required hardness uniformity. Specifics of gear geometry demand a particular process control algorithm. In the past, the process control recipe was limited to an available variation of power and scan rate vs. inductor position. Figure 3: Inductoheat’s STATIPOWER IFPt is a novel IGBT-type power supply Recent innovations bring the unique ability of Inductoheat’s novel specifically designed for induction hardening and tempering applications inverters to independently control both power and frequency allowing independently adjustable frequency via CNC-program in a 5-40kHz frequency range and power in the range of 10-360kW during scanning operation, which optimizes electromagnetic and thermal conditions at initial, intermittent, and final stages of scanning. As an example, Figure 3 shows the STATIPOWER® IFPt (Independent Frequency and Power Control) inverter. The ability to independently change the frequency and power of an induction system during the scanning process represents the long-awaited dream of commercial induction heat treaters, since such type of setup would provide the greatest process flexibility. STATIPOWER® IFPt is a novel IGBT-type power supply specifically designed for hardening and tempering applications, allowing independently adjustable frequency via CNC-program in a 5-40kHz frequency Figure 4: Contour hardened gears. (Courtesy of Inductoheat Inc.) range and power in the range of 10-360kW. This concept substantially expands heat treat equipment capabilities for processing parts by programming power and/or frequency changes on the fly, maximizing heating efficiency and temperature uniformity while heating complex geometry components.
Gear spin hardening (encircling inductors)
Spin hardening is the most popular approach for induction hardening gears with fine and medium-size teeth. Gears are rotated during heating to ensure an even distribution of energy. Single-turn or multi- turn inductors that encircle the whole gear can be used [1,3- 6]. When applying encircling coils, it is possible to obtain substantially different hardness patterns by varying process parameters. As a rule, when it is necessary to harden only the tooth tips, a higher frequency and high power density should be applied; to harden the tooth roots, use a lower frequency. A high power density in combination with the relatively short heat time generally results in a shallow pattern, while a low power density and extended heat time produces a deep pattern with wide transition zones. Quite often, to prevent problems such as pitting, spalling, tooth fatigue, and endurance and impact limitations, it is required to harden the contour of the gear, or to have gear- contour hardening (Figure 4). This often also maximizes beneficial compressive stresses within the case depth and dramatically minimizes distortion of as- hardened gears keeping it under 80-100 microns (0.003” – 0.004”). Many times, obtaining a true contour-hardened pattern can be a Figure 5: Inductoheat’s simultaneous dual frequency inverter for gear contour difficult task, due to the difference in current density (heat source) hardening. (Courtesy of Inductoheat Inc.) distribution and heat transfer conditions within a gear tooth.
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Figure 9: Carrier pin – simultaneous OD and ID hardening. (Courtesy of ERS Engineering Corp.)
Figure 7: Section of the induction hardened transmission gear.
(Courtesy of ERS Engineering Corp.)
power exceeds 1,200kW. As expected, smaller gears will require
less power. Heat time usually does not exceed 2 seconds and often is less than 1.5sec. Inductoheat’s simultaneous dual frequency induction gear hardening system (Figure 5) also has some “auto-match” features to Figure 8: Induction hardened automotive journal cross. simplify tuning. It is rugged and can be used for high-volume single- (Courtesy of ERS Engineering Corp.) shot hardening of a variety of powertrain components, dramatically minimizing distortion of heat-treated parts and providing a superior hardness pattern with favorable distribution of residual stresses. Simultaneous dual frequency gear hardening Some induction practitioners have heard about simultaneous dual A Novel Development in Induction Gear frequency gear hardening, which utilizes two appreciably different Hardening: TSH steels frequencies working on the same coil at the same time [6]. Low There was a belief that not all gears and pinions were well-suited frequency helps to austenitize the roots of the teeth and high for induction hardening. Hypoid and bevel gears, spiral bevel frequency helps to austenitize the teeth flanks and tips. automotive pinions, and noncircular gears used to be rarely However, it is not advantageous have two different frequencies induction hardened. Those gears were typically carburized. This working simultaneously all the time. In some cases, it is preferable situation has changed. As an example, Figure 6a and Figure 6b to apply lower frequency at the beginning of the heating cycle and show an example of inductively case-hardened components utilizing after achieving a desirable root pre-heating, the higher frequency TSH Technology [7,8]. can be used instead of or simultaneously with lower frequency, TSH steels are low-hardenability (LH) low-alloy steels, completing a job by working together. characterized by limited hardenability and a reduced tendency for Figure 5 shows Inductoheat’s single-coil dual frequency system, grain growth at austenizing temperatures suitable for hardening. comprised of medium- (10kHz) and high-frequency (120 to They can be substituted for standard steels typically used for 400kHz) modules working simultaneously, or in any sequence conventional induction hardening or carburizing grades. TSH desirable, to optimize properties of the heat-treated gears [6]. Total steels have significantly less alloying elements such as manganese,
About the Author: Dr. Valery Rudnev is Fellow of the American Society for Materials, and Group Director, Science and Technology, Inductoheat Inc., An Inductotherm Group Company. He is considered by many as one of the leading global figures in the induction heating industry. Dr. Rudnev has more than 30 years of experience in induction heating and is known within the American Society for Materials (ASM International) and among induction heating professionals as “Professor Induction.” His credits include a great deal of “know-how”, more than 30 patents, inventions, software registrations and more than 180 engineering/scientific publications. He co- authored the “Handbook of Induction Heating” published by Marcel Dekker, New York, 2003, 800 pages and six) chapters for several handbooks devoted to various aspects of induction heating, induction heat treating, computer modeling, and mathematical simulations. For more information, visit www.inductoheat.com
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molybdenum, chromium, and nickel than Progress, September, 2009, p.55-58. [6] R udnev, V., Single-coil dual frequency the majority of conventional low-alloy steels. [3] R udnev, V., Spin Hardening of Gears induction hardening of gears, Heat Their chemical composition is somewhere Revisited, Heat Treating Progress, ASM Treating Progress, ASM International, between micro-alloy steels and plain carbon Int., March/April, 2004, p.17-20 October, 2009, p 9-11 steels, providing fine-grain martensite with [4] Rudnev, V., Induction hardening of gears [7] Breakthrough contour hardening, ERS extremely high compressive stresses at the and critical components, Part 1, Gear Engineering brochure, 2011 tooth surface. Technology, p 58-63, Sept./Oct. 2008 [8] Brayman, S., Kuznetsov, A., Nikitin, S., With TSH technology, components are [5] Rudnev, V., Induction hardening of gears Binoniemi, B. and Rudnev, V., Contour usually through heated, or partial heated and critical components, Part 2, Gear hardening bevel, hypoid, and pinion gears, (depth of heating needs to be 2-3x deeper Technology, p 47-53, Nov./Dec. 2008 Gear Solutions, September, 2011, p. 30-35. than required harden depth) and then rapidly quenched. The hardened depth is mainly controlled by the steel’s chemical composition. Even though components made from TSH steels are often through- heated, their limited hardenability allows for obtaining crisp hardness case depth with a well-controlled hardness pattern having minimum case hardness deviations, even when hardening complex-shaped parts (Figure 7 and Figure 8). In the past, it was practically impossible to induction harden the components shown in Figures 6, 7, 8 and 9. Now it is possible ISO 9001-2000 Registered SINCE 1970 to get those impressive uninterrupted hardness patterns by using a simple operation: Through heating those parts using low frequency inverters and water quenching. Notice that spiral bevel pinion (Figure 6) was induction hardened on OD, ID, and teeth region using a single operation having a continuous hardness pattern. The carrier pin (Figure 9) was induction hardened on outside surface (1.25” diameter) and two inside diameters (longitudinal and transversal) using a single operation that also produced un-interrupted case hardness pattern. Inside diameter of longitudinal hole was 0.5“. The inside diameter of the transverse hole was 0.25” • Anneal • Straightening [7,8]. • Quench & Temper • Flame Hardening Conclusions • Carburize • Solution Anneal Induction heat-treating being • Normalize • Shot blasting environmentally friendly, green, and lean technology is an increasingly popular • Carbide Removal • Cryogenics choice for induction hardening of gears and • Stress Relieve • Vacuum Heat Treating gear-like components. Recently developed • Solution Treat and Age of Aluminum/Aerospace Specifications inverters and process know-how further expands its capabilities.
References [1] R udnev, V. and Loveless, D., Handbook of Induction Heating, Marcel Dekker, NY, 2003. Member 205-681-8595 [2] Doyon, G., Brown, D., Rudnev, V., Andrgea, F., Stilwala, C. and Almeida, pvht.com E., Induction heating helps to put wind turbines in high gear, Heat Treating
