Asynchronous Dual Frequency Induction Heating Of Lower Bevel Gear With Abnormal Coil Numerical Simulation And Experimental Study

For enterprises concerned about the high quality production and manufacturing of bevel gears,and striving to solve the uniformity problem of bevel gear surface hardening layer which is difficult to be solved by traditional carburizing and quenching technology and single frequency electromagnetic heating,this study is devoted to the coupling field setting of dual-frequency heating simulation and the influence mechanism of dualfrequency heating cycle mechanism on gear heating quality.The research focusing on the establishment of the electrical-magnetic-thermal multi-field coupling model for asynchronous dual-frequency electromagnetic induction heating of bevel gear under special-shaped coil,clarifying the heat source evolution mechanism,and constructing mathematical expressions between different process parameters and temperature field distribution rules,and establish the bevel gear asynchronous dual frequency induction heating temperature accurate control mathematical model.Breakthrough in key technologies such as verifying temperature field models through experimental detection,and predicting temperature field uniformity under different cyclic heating systems through experiments.Firstly,a simulation scheme for the asynchronous dual-frequency induction heating of the bevel gears is developed.The establishment of geometric model,the definition of element and material thermophysical parameters,mesh division,creation of physical environment and solution settings are studied by using the ANSYS finite element software.A dual-frequency electro-magnetic-thermal coupling numerical simulation model of the sprocket is established.Secondly,numerical simulation was used to compare and analyze the temperature field morphology of the bevel gear under the hood coil and the profiling coil after single frequency(medium frequency,high frequency)induction heating and asynchronous dualfrequency induction heating.The results show that the bell coil can well heat the tooth bottom of the bevel gear,and the profiling coil can simulate the tooth profile of the gear.Based on this,a technical scheme for asynchronous dual frequency induction heating of the bevel gear under the profiled coil is proposed.Thirdly,using numerical simulation,the asynchronous dual-frequency induction heating of bevel gears with irregular coils is studied.Process parameters such as medium to high frequency current frequency ratio,current density ratio,inductor geometric parameters,and medium to high frequency cycle state were analyzed,and the effects of various process parameters on the temperature field of asynchronous dual-frequency induction heating were obtained.The results show that during medium frequency induction heating,the movement of the internal heat source from the top of the tooth to the bottom of the tooth along the direction of the tooth profile is an accelerated process.When the workpiece temperature reaches the magnetic transition point temperature of the material,the temperature of the tooth top increases and the temperature of the tooth bottom decreases during high frequency induction heating.Moreover,various process parameters have a significant impact on the temperature field in the direction of tooth profile and heating layer depth.This provides a reference basis for the selection of process parameters for asynchronous dual frequency induction heating.Finally,a bevel gear asynchronous dual-frequency induction heating experimental platform was designed and built.Use thermocouples to measure temperature at key points on the surface of the gear teeth.The reliability of the numerical simulation model was verified by comparing experimental data with numerical simulation data.