Simulation of single and dual-frequency induction hardening of steel gear using ELTA

Induction heat treatment of gear is very effective technology to increase hardness of steel. A great deal of experimental and calculating research has been carried out and published [1-10]. Many researchers have been spent a great deal of time investigating processes of induction heating and quenching using 3D software to meet necessary temperature profile in tooth and hardening depth. 3D simulation is effective, but in many cases not very simple process especially if designer wants to find a fast rational decision of current problems. For example it is difficult to find integral parameters of inductor and visualize the field and power source distribution in the gear. In order to perform these tasks more efficiently, the authors offered new version of ELTA with special Gear Application. Process of investigation may be simpler and faster than in case of 3D simulation due to advantages of this program. It is very convenient to input the gear parameters as well as inductor and process parameters. An idea of 2D gear model and structure of ELTA 7.0 is described in this paper. ELTA provides very fast and reasonably accurate simulation of electromagnetic and thermal fields in induction heating using a combination of two-dimensional numerical (Finite Difference) approach and an analytical account for finite length of the part and induction coil (Total Flux Method). This program is effective for preliminary evaluation of inductor parameters and visualization the field and power source distribution in the gear. Several examples of investigation for single and dual-frequency heating of gears are presented. Results of simulation can give the required information about the power, frequency, heating and cooling time and predicted hardening depth of gear.