| With China's advancement toward a powerful equipment manufacturing industry,high-speed railways,aerospace,automation equipment and other equipment manufacturing industries are rapidly developing,and there is an urgent need to improve the technological level of basic components such as gears.Gears are the most widely used transmission parts in modern machinery.The gear transmission system has the advantages of high transmission efficiency,large power,stable operation and constant power.Made in China 2025 clearly proposes the full implementation of green manufacturing,development of clean heat treatment surface hardening technology,improvement the utilization of manufacturing resources.Compared with the gear carburizing process,the gear induction quenching process is green and environmentally friendly,and it has high production efficiency.It is easy to realize automation,and has advantages of high fatigue strength,high wear resistance,and small distortion.In this paper,the following research work has been done for the dual-frequency induction hardening process of bevel gears:(1)A three-dimensional finite element model of the bevel gear is established in the finite element software ANSYS.The method of segmented dual-frequency induction heating is selected,and the dual-frequency electromagnetic-thermal coupling analysis is implemented using the APDL language.According to the structural characteristics of bevel gears,according to the principle of gear induction coil design,a "Wrap around" induction coil designed for dual-frequency induction heating of bevel gears is designed and parameters are optimized.(2)This paper Analyses the characteristics of medium and high frequency induction heating,and compares single frequency induction heating method with dual frequency induction heating method.The dual-frequency induction heating process of bevel gears is investigated,and the influence of electric parameters such as medium and high-frequency current switching times and output time ratio on the dual-frequency induction heating process is analysed.(3)The DEFORM software is used to simulate the quenching process of bevel gears,and the depth and uniformity of hardened layer are quantitatively analysed from the distribution of bevel gear surface layers.(4)Using the lab's medium and high frequency induction heating power supply,a dual-frequency induction heating experimental platform is set up to carry out dual-frequency induction heating experiments of the bevel gears,and the temperature rise of 4 points on the outer surface of the tooth profile and tooth width direction is detected and recorded.The experimental data and simulation data are compared and error analysis is performed to verify the correctness of the finite element simulation. |
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