Surface Hardening Complex Components Using Multiple Energy Zones
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Solution Overview
Problem
Current surface hardening techniques, such as induction and laser beam hardening, are inadequate for components with complex shapes or abutting edges that have a three-dimensional profile, as they cannot adjust geometry and power density distribution effectively, leading to the formation of tempering zones that degrade wear and fatigue resistance.
Innovation Solution
A method and device utilizing multiple energy action zones guided by cooperating movement systems to create overlapping temperature fields, allowing for spatial and temporal control of power density distributions, enabling homogenous austenitization without tempering zones, using energy sources like lasers or inductive fields, and adjustable movement systems to accommodate complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional induction or laser beam hardening is used for components with complex shapes, then the process is simple, but tempering zones are formed that degrade wear and fatigue resistance
Solution Approach 1:
The patent applies segmentation by dividing the hardening process into multiple independently controllable energy action zones, each with its own movement system. This allows precise control over temperature fields in different regions, preventing tempering zones from forming while maintaining the ability to handle complex geometries without requiring an overly complex integrated system.
Solution Approach 2:
The patent implements dynamics by enabling independent adjustment of power density distributions and movement trajectories for each energy action zone. This dynamic control allows the system to adapt to varying local requirements on complex surfaces, ensuring uniform austenitization temperatures while avoiding tempering zones, thus improving reliability without excessive system complexity.
2Adaptability or versatility
If fixed geometry inductors or beam shaping systems are used, then the device is simple, but components with changing angles or 3D profiles cannot be hardened uniformly
Solution Approach 1:
The patent applies dynamics by making the power density distributions and movement trajectories of multiple energy action zones independently adjustable. This allows the system to adapt to complex geometries with changing angles and 3D profiles, achieving uniform austenitization without requiring permanently complex fixed geometry components.
Solution Approach 2:
The patent implements parameter changes by allowing independent adjustment of power density distributions for each energy action zone according to local requirements. This enables the system to handle components with varying angles and complex surfaces by modifying process parameters rather than replacing physical components, thus improving adaptability without excessive device complexity.
3Manufacturing precision
If multiple energy action zones with independent control are used, then uniform austenitization without tempering zones is achieved, but the system complexity increases
Solution Approach 1:
The patent applies segmentation by creating multiple independently controllable energy action zones, each with its own movement system. This division allows precise control over temperature fields in different regions, achieving uniform austenitization and preventing tempering zones while keeping each individual zone's control system manageable.
Solution Approach 2:
The patent implements parameter changes by enabling independent adjustment of power density distributions and movement trajectories for each energy action zone. This allows precise control over heating parameters in different regions, achieving manufacturing precision through parameter optimization rather than requiring overly complex mechanical control systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves continuous, stress-appropriate hardening zones with constant hardness across complex surfaces, preventing tempering zones and optimizing wear resistance and fatigue strength for components with multidimensional shapes.
Implementation Method 1
The functional surface to be hardened is exposed to the energy action zones of several laser beams or inductors
Implementation Method 2
The functional surface to be hardened is exposed to the energy action zones of several laser beams or inductors
Implementation Method 3
wherein the component is cooled down again in each case below the martensite start temperature
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3d
AI summary
The invention relates to the hardening of the surface layer of parts of machines, plants and apparatuses and also tools. Objects for which the application is possible and advantageous are components which are subjected to severe fatigue or wear stresses and are composed of hardenable steels and have a complicated shape and whose surface has to be hardened selectively on the functional surfaces or whose functional surface has a multidimensional shape. The process for hardening the surface layer of components having a complicated shape is carried out by means of a plurality of energy input zones. According to the invention, it is characterized in that the energy input zones are conducted on different curved parts separately in space and time and by means of cooperatively working transport systems so that superposition of the individual temperature fields forms a uniform temperature field which completely covers the functional surface of the component and within which each surface element of the later hardening zone of the component attains the selected austenite formation temperature interval ?Ta at least once and the time interval ?t between the maximum temperatures Tmaxn of the individual temperature fields is from 3.1 to 3.n smaller than the time ?tmS which is required to go below the martensite start temperature MS during the cooling phase. The apparatus by means of which the process of the invention can be carried out is, according to the invention, characterized in that the energy configuring units are connected to one or more energy sources for optical or electromagnetic radiation and are each fixed to separate but cooperatively operating transport systems.