Professional Documents
Culture Documents
A high-speed infrared camera with software to calibrate, freeze and record temperatures after each heat cycle is used as a diagnostic tool to develop a process for profile hardening gears or gear-like objects. The method can eliminate costly and most often destructive examination.
ombining process monitoring and a diagnostic tool to develop a process for contour (profile) hardening gear teeth or toothlike objects on parts having gear-like geometry can eliminate costly and most often destructive quality checks. The process tool is an extension of the dual pulse induction hardening (DPIH) process. A high-value gear requires a hard wearresistant surface with a soft core. A gear transmits torque, so its teeth are subjected to a combination of cyclic bending, contact stresses, and different degrees of sliding or contact behavior. This makes it critical for a gear to have a proper case/core structure, a condition that can be achieved using a surface hardening process, such as induction hardening, which is discussed in this article. Contour gear hardening processes are currently performed using one or two power supplies. The process goal is to achieve a uniform case depth both at the root, as well as along the pitch diameter and the tip. This pattern uniformity is achieved by maintaining a definite range of temperatures between the tip and the root area, which depends on the geometry, pitch, and other gear characteristics.
Samples were sectioned and the K ratios were measured. Table 2 shows case depths at two critical areas and their corresponding ratio. Sample number 15 is an ideal profile hardened sample, while number 18 has no case at the root, and sample number 20 has a through hardened gear pattern. Figure 3 shows two examples of gears having different K ratios. The gear at the top has a heavy case at the tip, similar to sample number 18, while the gear at the bottom has a more pronounced case at the tip (also known as through hardened) similar to sample number 20. Gears are sectioned in all contour hardening processes to examine the hardened profile until achieving a profile pattern as in Fig. 2. This destructive process is not only part of process development (Fig. 4), but also it is used during a production run, where parts are cut at regular intervals to monitor quality.
32
GEAR SOLUTIONS
JULY 2007
gearsolutionsonline.com
gearsolutionsonline.com
JULY 2007
GEAR SOLUTIONS
33
Induction U.S.A.
Figure 3 Different hardening patterns on gears resulting from using different process variables
Lowest Energy Consumption True Prole Hardening Fastest Cycle Times Accurate and Reproducible Single Piece Work Flow Far Less Distortion Minimize / Eliminate Post-Machining
Figure 5 Diagnostic tool used for process development consists of a high-speed infrared camera with software to calibrate, freeze, and record temperatures at the end of preheat, the end of soak, and at the end of final heat cycles
Figure 6 Visible heat pattern on gear during the final heating stage of the hardening process
Induction U.S.A.
B
Table 2 Test results from sectioned contour hardened gears using different process variables Figure 7 Monitoring temperatures during contour hardening; uniform heating of root and tip (a) and heat pattern during the heating cycle (b)
gearsolutionsonline.com
ling the settings (power and time), an exact heat cycle can be defined without cutting gear samples to verifying case depths. It is possible to achieve the desired profile hardening pattern in gears by monitoring the surface temperatures at speciFigure 8 Nonuniform heating fied regions. Figures 6, 7 and 8 illustrate the different stages of heating at the surface of a gear and soaking cycle during processing of a gear. Regions of nonuniform heating at the surface of the gear are shown in Fig. 8, which indicate that the process is far from optimum. The DPIH process or any other gear profile hardening processes can be optimized using the proposed type of diagnostic tool, which will result in a uniform temperature between the root area and Figure 9 Temperature record- tip region. Figure 9 shows such a ed by infrared camera shows process developing step. more uniform heating at the The DPIH process was used to gear tip and root heat treat gears at various levels of preheat time, soak time and power levels. The high-speed camera measured temperatures at four critical areas of the gear (Fig. 10). By comparing the temperatures of the four areas, an optimum process setting was possible for that particular gear. The process was verified by sectionFigure 10 Temperature is ing samples at different heat treat measured at the gear root, tip, process variables. Figure 11 shows flank, and corefour critical cross sections of gears having different hardened profiles resulting locationsto establish optifrom using different power settings mum process settings. for each gear. The other characteristics of this process is a closed-loop system that sends a signal to the power supply to alter the process frequency (variable frequency process), or to adjust the ratios of the amount of high to lower frequency (simultaneous frequency process) at different power settings. This allows the process to be altered during the heating cycle. Figure 12 shows a series of photos at different stages during profile hardening of a gear using simultaneous dual frequency. Both the frequencies and amount of power were altered to achieve uniform surface temperatures at critical regions to achieve a uniform contoured hardening pattern.
Figure 11 Gear cross sections show various hardening profiles resulting from different power settings. gearsolutionsonline.com JULY 2007 GEAR SOLUTIONS 35
Summary
The proposed method depends on measuring temperatures of critical areas and comparing them with established temperatures required to obtain a contoured gear pattern. Temperature profiles from these regions send signals through a closed-loop system to the power supply to alter power level, heat time, and also the frequency of the power supplies. By adjusting the frequencies of the power supplies, the power levels, and the heat times, a contoured or a profile gear pattern can be achieved (Fig. 13). The process is a nondestructive method.
REFERENCES:
Figure 12 Different stages during profile hardening of a gear using simultaneous dual frequency; root heating (a), tip heating (b), tip heating and more intense root heating (c), and uniform heating along the gear contour by adjusting process variables (d)
1. U.S. Patent 4,639,279 (example); Chatterjee, M.S. 2. U.S. Patent 5, 428,208; Chatterjee, M.S., et. al. 3. GPC 2002; Dinwiddie, R. and Chatterjee, M.S.
< Stable and meta-stable phase equilibrium THERMO-CALC IS A POWERFUL < Liquidus and solidus temperatures < Scheil solidication SOFTWARE TOOL FOR < Phase properties < Thermochemical data THERMODYNAMIC CALCULATIONS. < Thermodynamic predictions < Evaluation of thermodynamic data < Databases for Fe-, Ni-, Al-, Ti-, Mg- based alloys, solders, refractory oxides, and more
Homogenization > Carburizing & Decarburizing > Nitriding > Microsegregation > Dissolution of precipitates > Coarsening of precipitates > Interdiffusion and phase transformation kinetics > Databases for Fe-, Al- and Ni- based alloys >
Please visit us at Booth #837 MS&T / ASM Heat Treat 2007 Detroit, MI Sept 18-19, 2007
USA, Canada and Mexico: E: Paul@thermocalc.com P: (724) 731 0074 F: (724) 731 0078 Rest of the World: E: info@thermocalc.se P: +46-8-545 959 30 F: +46-8-673 37 18
thermocalc.com
JULY 2007 GEAR SOLUTIONS 37
gearsolutionsonline.com