Numerical Modeling of Steel Surface Hardening in the Process of High Energy Heating by High Frequency Currents

Abstract:

Surface layer modification methods using concentrated energy sources to ensure high heating rates of approximately 10⁴ – 10⁵ °C/s are becoming increasingly common in an attempt to improve operational performance of machine components. As a result, it is quite difficult to determine heat cycle parameters by means of experiments to predict the required intensity and distribution behavior of residual stresses and strains. The paper addresses the issue of numerical simulation of the stress-strain behavior during high energy heating by high frequency currents (HFC HEH). A finite element model has been generated using the ANSYS and SYSWELD software based on numerical computations of differential equations for transient heat conduction (Fourier equation), carbon diffusion (Fick's second law), and the elastic-plastic behavior of the material. The simulation data was verified by full-scale experiments using optical and scanning microscopy and mechanical and X-ray methods to determine residual stresses. It has been established that the level of residual compressive stresses on the component surface can be from-500 to-1000 MPa within the range of HFC HEH process variations under review. It is proven in theory and confirmed by experiments that the transition layer thickness must amount to 25 – 33 % of the hardened layer depth for the tensile stress peak to shift to deeper material layers while compressive stresses on the surface decrease by 6 – 10 %, in order to prevent hardening cracks.

References

[1] J.R. Davis, Surface Hardening of Steels: understanding the Basics, Materials Park, ASM International, Ohio, (2002).

[2] M.G. Golkovskii, Hardening and cladding of a relativistic electron beam outside the vacuum, Technological capabilities of the method, LAPLAMBERT Acad. Publ., Saarbrucken, (2013).

[3] I.A. Bataev, M.G. Golkovskii, A.A. Bataev, A.A. Losinskaya, A.I. Popelyukh, E.A. Drobyaz, Surface hardening of steels with carbon by non-vacuum electron-beam processing, Surface and Coatings Technology. 242 (2014) 164–169.

DOI: 10.1016/j.surfcoat.2014.01.038

[4] V.I. Rudnev, D. Loveless, 12. 15 – Induction Hardening: Technology, Process Design, and Computer Modeling, Comprehensive Materials Processing. 12 (2014) 489–580.

DOI: 10.1016/b978-0-08-096532-1.01217-6

[5] V.V. Ivantsivskii, V.A. Bataev, Surface hardening of machine parts by using high-energy heating by high frequency currents, Polzunov Bulletin (in Russian) 2-2 (2005) 104-112.

[6] F. Cajnera, B. Smoljanb, D. Landeka, Computer simulation of induction hardening, Journal of Materials Processing Technology. 157–158 (2004) 55–60.

[7] D. Coupard, T. Palin-Luc, P. Bristiel, V. Ji, C. Dumas, Residual stresses in surface induction hardening of steels: comparison between experiment and simulation, Materials Science and Engineering: A. 487 (2008) 328–339.

DOI: 10.1016/j.msea.2007.10.047

[8] M. Schwenk, J. Hoffmeister, V. Schulze, Experimental Determination of Process Parameters and Material Data for Numerical Modeling of Induction Hardening, Journal of Materials Engineering and Performance. 22 (2013) 1861-1870.

DOI: 10.1007/s11665-013-0566-3

[9] V.V. Ivancivsky, V. Yu. Skeeba, N.P. Stepanova, Assignment mode of surface hardening, which is carried out by using a concentrated heat source, Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) (in Russian) 28 (2005) 22-24.

[10] V.V. Ivancivsky, V. Yu. Skeeba, V.N. Pushnin, Methods of appointment processing conditions when combining the operations of abrasive grinding and surface induction hardening, Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) (in Russian) 53 (2011).

[11] Ya.L. Lifshits, V.S. Kraposhin, Ya.L. Linetskii, Physical properties of metals and alloys: Directory, Metallurgiya Publ., Moscow, (1980).

[12] V.E. Zinov'ev Thermophysical properties of metals at high temperatures: Handbook, Metallurgiya Publ., Moscow, (1989).

[13] V.G. Sorokin, M.A. Gervas'ev, Grade steels and alloys. Reference Edition, Intermet Engineering Publ., Moscow, (2001).

[14] S. Denis, S. Sjöström, A. Simon, Coupled temperature, stress, phase transformation calculation model numerical illustration of the internal stress evolution during cooling of a eutectoid steel cylinder, Metallurgical and Materials Transactions: A. 18 (1987).

DOI: 10.1007/bf02647190

[15] R. Fortunier, J.B. Leblond, J.M. Bergheau, A Numerical Model for Multiple Phase Transformations in Steels during Thermal Processes, Journal of Shanghai Jiaotong University. 1 (2000) 213–220.