Numerical Simulation And Experimental Study On High Frequency Induction Heating Process Of Helical Gear Of Heavy Duty Truck Transmission

With the rapid development of my country’s automobile industry,heavy-duty vehicles are gradually developing in the direction of high-power and heavy-duty,and the requirements for the use performance of transmissions are also increasing.Transmission helical gears are often exposed to harsh conditions such as high temperature,variable load and poor lubrication conditions.Under the circumstances,it is easy to be damaged and fail.The quality of gears depends to a large extent on the heat treatment process.Setting reasonable heat treatment process parameters plays a vital role in improving the load-bearing capacity,wear resistance and surface hardness of helical gears in heavy-duty automobile transmissions.Induction heating quenching technology has become the best choice for gear surface hardening process due to its advantages of energy saving,high efficiency,clean and pollution-free,and easy to realize industrial automation.In this paper,the electromagnetic field and temperature field theory involved in the induction heating process are deeply studied.The finite element software ANSYS is used to simulate the variable speed spiral high-frequency induction heating process of the helical gear,and the method of combining numerical simulation and experiment is analyzed.The influence of various factors on the quality of induction heating of helical gears,the research work involved includes:First,based on the design principles of induction coils,combined with the structural characteristics of helical gears,a 1/4-tooth-width profiling induction coil for helical gear speed helical high-frequency induction heating is designed,and the overall structural parameters of the coil are optimized Aaccording to the relationship between the electromagnetic field and the temperature field in the high-frequency induction heating process of the helical gear,a three-dimensional finite element model of electromagnetic-thermal-motion coupling analysis is established,and the "dynamic coordinate system" method is proposed to be equivalent to the variable-speed spiral motion of the helical gear,and Based on the "dynamic coordinate system" method for geometric modeling,meshing,loading and solving.Secondly,use ANSYS finite element software to compile APDL language of electromagnetic field,temperature field and sports field to realize dynamic simulation of helical gear high-frequency induction heating process,and analyze in detail the temperature in the middle section of the initial heating position of helical gear and along the tooth width direction distribution characteristics.Using ANSYS finite element software to compare and analyze the influence of the overall heating method and the layer-by-layer heating method on the heating quality of the helical gear,simulate the layer-by-layer heating process of the helical gear by the 1/4 tooth width profiling induction coil,and summarize the different geometries The influence of parameters,motion parameters and electrical parameters on the temperature distribution of helical gears along the tooth width direction and along the tooth profile direction.Finally,use the laboratory’s induction heating equipment and the 1/4 tooth width profiling induction coil to carry out the helical gear variable speed spiral high-frequency induction heating experiment,and carry out the corresponding numerical simulation according to the process parameters used in the experiment.The temperature data obtained is compared with the experimental data to verify the accuracy of the numerical simulation.