OBRABOTKA METALLOV

Abstract
Purpose: To increase the performance properties of the machine parts, part surface layer modification methods are becoming more and more popular. They use concentrated energy sources to achieve high heating rates of around 10⁴ to 10^{5 o}C/s. Therefore, it is rather difficult to experimentally determine the values of the heat cycle parameters that are needed to predict the required size and character of the residual stress distribution and deformation. The task of this paper is to numerically model the stress-strain state of the material under high energy heating by high-frequency currents (HEH HFC). Methods: The finite element model was created in the ANSYS and SYSWELD software complexes that use numerical methods to solve differential equations of transient heat conduction (Fourier equation), carbon diffusion (Fick’s second law) and elastoplastic material behavior. The modeling results were verified by means of natural experiments using optical and scanning microscopy, mechanical and X-ray methods to detect residual stresses. Results and Discussion: It was established that in the observed change range of the HEH HFC modes, the level of residual compression stresses on surfaces of parts may achieve the values of -500 to -1000 MPa. It was theoretically proven and experimentally confirmed that the size of the transition layer should constitute 25 to 33 % of the hardened layer depth, which shifts the peak of the tension stresses to the deeper layers of the material while decreasing the compression stresses on the surface by 6 to 10 % and excluding the possibility of heat treatment crack formation.

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