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Gear-hardening

Gear-hardening

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00 GEAR TECHNOLOGY November/December 2008 www.geartechnology.com 4 8 in combination with short heat time (Fig. 10, left). To harden the tooth roots, use a lower frequency (Fig. 10, right). A high power density generally gives a shallow pattern, while a low power density will produce a deep pattern with wide transition zones. Hardness pattern uniformity and repeatability depend strongly on the relative positions of gear and induction coil and the ability to maintain the gear concentric to the coil. Gear Quenching Induction hardening is a two-step process: heating and quenching. Both stages are important. There are three ways to quench gears in spin hardening applications (Ref. 1): • Submerge the gear in a quench tank. This technique is particularly applicable for large gears. • Quench "in place" using an integrated spray quench. Small- and medium-size gears are usually quenched using this technique. • Use a separate, concentric spray-quench block (quenchring) located below the inductor. Note that the widely published, classical cooling curves that represent the three stages of quenching—vapor blanket, boiling and convection heat transfer—cannot be directly applied in spray quenching (Ref. 7). Due to the nature of spray quenching, the fi rst two stages are greatly suppressed. At the same time, cooling during the convection stage is more severe. Tooth geometry and rotation speed are other factors that have a pronounced effect on quench fl ow and cooling severity during gear quenching. It is also important to avoid both eccentricity of the inductor and quench system relative to the gear and gear wobbling. Even with gear rotation, gear wobbling will cause a specifi c part of the gear to be hotter during heating, because regardless of rotation it will always be closer to the coil. Besides non-uniform heating, wobbling also causes uneven quenching, leading to additional hardness non-uniformity and gear shape distortion. It has been reported that more favorable compressive stresses within the tooth root were achieved with the gear spin hardening technique than with the "tooth-by-tooth" or "gap- by-gap" approaches.
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