Numericalsimulation And Experimental Study On Heating Process Of Heavy-duty Sprocket By Profile Sensor

At present,China is developing in high speed,which can't advance without the assistance of construction machinery,and he working environment of the construction machinery is usually bad.As the important part of power transmission,the sprockets prone to wear,fracture and other issues in their teeth during the long-term work,the problems greatly affected the progress of the project and even bring security risks,so the surface performance of sprocket must be improved,in order to meet the needs of the work,the surface wear resistance,hardness,fatigue strength and other performances must be improved.Sprockets are mostly made by casting,the internal material of the casting parts is well organized after the modulation,isothermal annealing working procedure,but it is necessary to have high wear resistance,hardness and fatigue strength,which can't come true without the surface hardening.Compared to the traditional quenching method,induction hardening has the advantages of high efficiency,energy saving,environmental protection and easy to realize automation.After the quenching,their probably come the issues that he contour prone to crack,hardened layer depth is not uniform,the hardness is not uniform and other issues,but the ideal scraper hardening layer distribution should be continuous,its thickness must be uniform,and it must be profiled along the tooth.The internal temperature field can be predicted in advance by numerical simulation,the internal temperature and the heating depth can be adjusted by changing the electrical parameters and geometric parameters,which have important guiding significance to the quenching of sprocket.In this paper,the following research work is carried out on the induction heating process of heavy chain sprockets:1)The principle of induction heating and the simulation process are introduced in detail,including the establishment of models,grid division,the definition of load,solution and other steps.Take the temperature distribution,temperature difference of the tooth profile and its internal 3mm layer,the heating depth of the three paths including the toothtop to the center of the circle C1-C1,from the tooth top 2/3 teeth height C2-C2,and tooth groove to the center C3-C3 as the standards for evaluating the quality of heating.2)Combined with the advantages and disadvantages of traditional induction coil,this paper designed a profiled coil with V-shaped angle,and the mathematical model of electro-magnetic-thermal coupling field can was established by ANSYS,the geometrical parameters of the induction coil and the incoming electrical parameters are mainly simulated.The effects of various factors on the magnetic induction intensity,temperature difference,heating depth and heating time of the hardened layer were analyzed.The importance of different factors on the sensitivity of induction heating is compared and analyzed,which provides the theoretical basis for the parameter modification of the sensor and the change rule of sprocket temperature with the change of parameters during the process of the induction heating.3)The induction heating experiment of the sprocket was carried out by using the IF power supply combined with the produced sensor,the temperature of the five points of the sprocket contour is measured by the temperature measuring device,then perform numerical simulations according to the experimental parameters.The measured data and the simulated data are plotted as curves respectively,then compared and analyzed the temperature curve of the 5 temperature measurement points,finally the error analysis was performed and the correctness of the simulation was verified.