Induction Hardening Simulation Of Crankshaft

To increase the efficiency of an engine development process, Numberical simulation is necessary. Several tools have been used for the successful optimization of different engine parts. With the advent of powerful computers, analysis based on finite element method has come into use for crankshaft design. The main invalidation of the crankshaft is fatigue rupture and severe abrasion. The crankshaft mainly subjects alternating loads, which are bending load, torsion load and some impact load. And the surface of journal also subjects strong abrasion. Therefore, in order to improving fatigue strength and abrasion-proof of the crankshaft, the induction hardening is applied to the crankshaft. The induction technique has several inherent advantages for heat treating vehicle components. Induction heating produces only internal heat sources. These sources provide high power densities and high selectivity of heating in the depth and along the surface of the part, which is very important for local heat treating. Induction heating is a common method for thermal processing of metals due to its efficiency and flexibility. The induction hardening process involves a complex interaction of electromagnetic heating, rapid cooling, metallurgical phase transformation and mechanical behavior, Many factors including coil design, power frequency, scanning velocity, workpiece geometry, material chemistry, and quench severity determine a process outcome. However, effective development of induction hardening requires extensive knowledge of electromagnetic, heat transfer, metallurgical transformations, and mechanics. A computer simulation model provides a cost effective approach for understanding and optimizing induction hardening. With a careful combination of simulation and experiments, a process can be optimized for energy efficiency and for residual stress and distortion patterns in a component. In this paper, ANSYS/Multiphysics software from ANSYS.Inc. is used to simulation induction hardening of a 6110 crankshaft. ANSYS/Multiphysics allows engineers to simulate various physical phenomena using finite element analysis (FEA). Including the interaction (coupling) between the phenomena. In this simulation, electromagnetic –thermal coupling and thermal-stress are used .Where the software predicts the Joule heat generated by Eddy currents at the surface of the crankshaft. Which in turn are caused by current flowing in the coil surrounding the crankshaft. The electromagnetic model consists of the crankshaft, the coil, and the surrounding air. Current is applied to the finite elements making up the coil at a specified frequency, and an electromagnetic harmonic analysis is performed. The program calculates the electromagnetic field caused by the current, as well as the Eddy currents at the surface of the crankshaft and the resulting Joule heat. This is followed by a transient thermal analysis which calculated the temperature distribution in the crankshaft due to the previously calculated joule heat. Since the electromagnetic properties of the crankshaft...