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What defects commonly occur in gears after quenching with electromagnetic induction heating equipment? How can these defects be prevented?
Release time:
2023-12-22
After the gears have undergone surface hardening using electromagnetic induction heating equipment, they first undergo several quality inspections, such as examining the chemical composition of the raw steel material, the core hardness of the gears, the surface hardness, microstructure and overall quality, as well as the depth of the hardened layer, to determine whether these parameters meet the specified technical requirements.
After gears undergo surface hardening using electromagnetic induction heating equipment, they first undergo several quality inspections, such as examining the chemical composition of the raw steel material, the core hardness of the gear, the surface hardness, microstructure and overall quality, as well as the depth of the hardened layer, to determine whether these parameters meet the specified technical requirements. However, not all gears that have undergone quenching will pass inspection, because during the quenching heat treatment process, various factors—including material properties and operational procedures—can lead to common quality defects in the gears. To address these defects, we will implement appropriate corrective measures.
1. The surface hardness is uneven, which is due to the non-uniform distance between the induction coil and the gear during induction hardening, as well as the presence of banded structures precipitated within the raw steel material. Local oxidation and decarburization have also occurred. Additionally, during heating and cooling, the temperature was either too high or too low, and the gear was not heated uniformly. To address these issues, we must first inspect the quality of the steel before production begins. Before quenching, the gears should be thoroughly cleaned to remove any oil, grease, or rust from their surfaces. The spray holes on the induction coil must be evenly distributed, and their interiors should be checked regularly to ensure they are not blocked. During quenching heating and cooling, the temperature must be kept uniform, and operations must be carried out in strict accordance with the specified standards.
2. Cracks have appeared on the gear surface due to quenching, which is caused by excessively high quenching temperatures leading to local overheating. Additionally, the selected production material has an excessively high carbon content and uneven composition; furthermore, during tempering, adequate tempering treatment was not carried out in a timely manner. To address this issue, we must choose an appropriate quenching medium based on the raw materials and follow standardized procedures for cooling treatment. It is crucial to strictly control the quenching temperature—neither too high nor too low—and to adjust the shape of the induction coil on the electromagnetic induction heating equipment promptly according to the gear’s geometry.
3. If the hardness of the gear surface is too high or too low, this may be due to either an excessively high or low carbon content in the raw material, improper heating temperatures during quenching, or failure to adhere strictly to the required temperature and duration during tempering. To address this, we need to adjust the hardness according to the specified requirements; select an appropriate cooling medium; and carry out the tempering process in accordance with the prescribed tempering specifications.
4. The hardening layer is not deep enough. This is due to the excessively high frequency of the induction heating equipment, the heating duration being too short, and the failure to select an appropriate cooling medium when the gear is cooled. To address this issue, we need to choose suitable electromagnetic induction heating equipment and promptly adjust the heating parameters to meet the standard requirements. Additionally, we should select an appropriate cooling medium for the cooling process.
5. Deformation occurs due to improper heating procedures or the selection of an unsuitable cooling medium. To address this, we must follow standard heating procedures and choose an appropriate cooling medium to ensure that the gear is heated and cooled uniformly.
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