Induction Heating Tooling for Quenching Warping Control

Solution Overview

Problem

Maintaining dimensional tolerances during heat treatment of structures is challenging due to warping issues during quenching, which can lead to increased manufacturing time and waste when excess material is removed to achieve the desired shape.

Innovation Solution

A tooling die system comprising dielectric laminates, a ceramic facing, and contoured smart susceptors with induction coils, which allows for controlled heating and quenching by maintaining the structure's shape through air gaps and efficient heat transfer, minimizing warping and material waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If quenching is performed to achieve desired material characteristics, then material properties are improved, but dimensional tolerances deteriorate due to warping

Engineering Contradiction:

Improvematerial characteristicsVSAvoiddimensional tolerances

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The structure is heated to the desired temperature and held in a heating fixture before quenching. This preliminary heating and positioning action ensures the structure is ready for quenching while maintaining dimensional stability, preventing warping during the subsequent cooling process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A heating fixture serves as an intermediary device between the structure and the quenching medium. The fixture provides controlled heating and maintains the structure in a fixed position during quenching, preventing direct contact between the structure and quenching medium that would cause warping.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If heat treatment is avoided to maintain dimensional tolerances, then manufacturing precision is maintained, but material characteristics deteriorate

Engineering Contradiction:

Improvedimensional tolerancesVSAvoidmaterial characteristics

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The structure is heated to the desired temperature and held in a heating fixture before quenching. This preliminary heating and positioning action ensures the structure is ready for quenching while maintaining dimensional stability, preventing warping during the subsequent cooling process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A heating fixture serves as an intermediary device between the structure and the quenching medium. The fixture provides controlled heating and maintains the structure in a fixed position during quenching, preventing direct contact between the structure and quenching medium that would cause warping.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If excess material is removed after quenching to achieve desired shape, then dimensional tolerances are improved, but manufacturing time and waste increase

Engineering Contradiction:

Improvedimensional tolerancesVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The structure is heated to the desired temperature and held in a heating fixture before quenching. This preliminary heating and positioning action ensures the structure is ready for quenching while maintaining dimensional stability, preventing warping during the subsequent cooling process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A heating fixture serves as an intermediary device between the structure and the quenching medium. The fixture provides controlled heating and maintains the structure in a fixed position during quenching, preventing direct contact between the structure and quenching medium that would cause warping.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The solution effectively maintains the structure's shape during heat treatment and quenching, reducing manufacturing time and waste by ensuring precise dimensional control and efficient cooling processes.

Implementation Method 1

The induction coils are disposed in some of the air gaps formed between adjacent dielectric laminates, wherein each induction coil of the induction coils extends through a single air gap

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

A tooling die system comprising dielectric laminates, a ceramic facing, and contoured smart susceptors with induction coils, which allows for controlled heating

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 3

quenching is performed by contacting the structure with a quenching medium

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 4

efficient heat transfer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10968497B2Tool for heating and quenching a structure

Publication Date: 2021.04.06 THE BOEING CO

AI summary

A structure is heated in a tool. The structure is quenched in the tool such that a shape of the structure is maintained, in which quenching is performed by contacting the structure with a quenching medium.