WHAT IS INDUCTION HARDENING?
Induction hardening is a process used for the surface hardening of
steel and other alloy components. The parts to be heat treated are
placed inside a copper coil and then heated above their
transformation temperature by applying an alternating current to
the coil. The alternating current in the coil induces an
alternating magnetic field within the work piece which causes the
outer surface of the part to heat to a temperature above the
transformation range.
The components are heated by means of an alternating magnetic field
to a temperature within or above the transformation range followed
by immediate quenching. It is an electromagnetic process using a
copper inductor coil, which is fed a current at a specific
frequency and power level.
THE TECHNICAL PARAMETERS OF THE INDUCTION HEATING MACHINE:
Model | GYD-250AB (Three phase) |
Work power | 340V-430V |
Maximum input current | 375A |
Output power | 250KW |
Fluctuating frequency | 30-80KHZ |
The flow rate of cooling water | 0.08-0.16Mpa 12L/Min |
Water temperature protection point | 50C |
Product size | main : 1090*650*1610MM |
transformer : 1070*480*850MM |
Net weight | main : 258kg |
transformer : 178kg |
APPLICATIONS OF INDUCTION HEAT TREATMENT MACHINE:
The induction hardening process has several heating methods and all
have suitable heating workpieces.
One-time induction heating hardening method:
- One-time induction heating or simultaneous induction heating is the
most common induction hardening method. When this method uses two
rectangular tubes surrounding the workpiece surface for rotary
heating, it is conventionally called a Single Shot.
- The advantage of this induction heating method is to complete all
the workpiece surface area induction heating jobs at a time.
Therefore, its operation is simple, productivity is high, and it is
suitable for heating the workpiece area is not too large. For
heating the particularly large area workpiece, adopt the one-time
heating method, it requires considerable power and high investment
cost.
- The most common examples of one-time induction heating hardening
are small and medium modulus gears, CVJ bell-shaped shell bars,
inner raceways, carrier wheels, support wheels, leaf spring pins,
pullers, valve ends, and valve rocker arm arcs, etc.
Scanning induction hardening method:
- When the workpiece heating area is large, and the induction heating
power supply is small, this method is often used. At this point,
the calculated heating area S refers to the region contained by the
induction ring. Therefore, with the same power density, the
induction heating machine required power is small, the competitive
induction hardening equipment investment cost is low, suitable for
small batch induction hardening production, typical examples are
large-diameter piston rod, corrugated roll, roll, oil pipeline,
sucker rod, rail, machine tool guide rail and so on.
Subsection one-time induction heating quenching method:
- Typical examples are the multiple camshafts induction hardening,
each time heat one or more cams, after finish this time induction
quenching, heating another cam part, the gears are hardened tooth
by tooth can also be included in this category.
Subsection induction scanning hardening method:
- Typical examples are valve rocker shafts or variable speed shafts
induction hardening, where multiple parts of a shaft are scanned
for induction quenching, the quenching widths may be different, and
tooth by tooth scanning quenching may also be included in this
category.
Induction heating and hardening in liquid:
- Induction hardening in the liquid, means the induction coil and the
workpiece heating surface are immersed in the induction hardening
liquid, heated, due to the heating surface power density being
greater than the surrounding quench fluid cooling rate. Therefore,
the surface heats up quickly. When the inductor is powered off, the
surface of the workpiece is hardened due to the heat absorption of
the workpiece core and the cooling of the hardening fluid.
- This method is generally suitable for steel workpiece which
requires a less critical cooling rate. When the workpiece is placed
in the air and the induction coil is powered off, the heat of the
surface is absorbed by the center of the workpiece. When the
cooling rate of the heated surface is greater than the critical
cooling rate, the workpiece is hardened, which is similar to the
quenching in the liquid.
ADVANTAGES OF INDUCTION HEAT TREATMENT MACHINE:
Short heating times
- Production rates can be maximized.
Optimized consistency
- Induction heating eliminates the inconsistencies and quality issues
associated with open flame, torch heating, and other methods.
Extended fixture life
- Induction heating delivers heat to very small areas of your part
without heating any surrounding parts. This extends the life of the
fixturing and mechanical setup.
Environmentally sound without burning fossil fuels
- Induction is a clean, non-polluting process. Improves working
conditions for employees by eliminating smoke, waste heat, noxious
emissions, and loud noise.
Effective energy consumption
- This uniquely energy-efficient process converts up to 90% of the
energy expended energy into useful heat; batch furnaces are
generally only 45% energy-efficient. Requires no warm-up or
cool-down cycle.
Flexible adaptation to the hardening tasks
Closed loop computerized process control and compatibility with
overall process automation