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DEPARTMENT OF MECHANICAL ENGINEERINGDILI INSTITUTE OF TECHNOLOGY – TIMOR LESTE

RESEARCHThe Effect of Temperature Induction Surface

Hardening To the Distortion of Gear

NATALINO FONSECA D. S. GUTERRES

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CONCLUSION

REFERENCES

INTRODUCTION

EXPERIMENTAL METHODS

RESULTS AND

DISCUSSIONS

Aircraft industry

Application gear in many industries

3(Ref: Robert L. Mott 2013).

INTRUDUCTION

Automotive industry

The gears are very useful in a variety of industries such as automotive industry, aircraft industry and the manufacturing machines and others. As a function to transmitting motion and power from one rotation shaft to another.

Manufacturing machines

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(Ref: Davis 2005) and Krantz & Kicher 2002)

(Ref : Robert L. Mott 2013)

INTRUDUCTION

When two gears contact each other, gear teeth must

also be capable of operating for the desired life

without significant pitting of the tooth form.

Repeated application of these high contact stresses

can cause a type of fatigue failure of the surface,

resulting in local fractures and an actual loss of

material.

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Induction Surface Hardening

Through hardening

(Ref: A. K Rakhit 2000)

Carburizing hardening

One of the most important processes in manufacturing to produce gears is heat treatment process.

INTRUDUCTION

STUDI LITERATUR

6(Rudnev, 2003)

What is induction hardening ?Induction heating is the process of heating an electrically conducting object by electromagnetic induction, where eddy currents are generated within the metal and resistance leads to Joule heating of the metal.

An induction heater consists of an induction coil (or electromagnet), through which a high-frequency alternating current is passed.

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Hardening process by indution heating causes a geometric distortion in gears.(Haimbaugh, 2001).

Ref. (Funatani 2009) & (Totten, 1993)

One way to extend the life of the gear is to minimize distortion during the manufacturing process, especially the process of induction surface hardening.

INTRUDUCTION

Expansion

Contraction

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SPECIMENT GEARS

The study begins with the preparation of speciment such as three gears (self manufactured), gear A for the temperature 8200C, gear B for the temperature 8800C and gear C for the temperature 9200C

Gear A for the temperature

8200C, 48 kHz and 35 sec

Gear B for the temperature

8800C, 49 kHz and 45 sec

Gear C for the temperature

9200C, 50 kHz and 55 sec

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INDUCTION HARDENING PROCESS

Before going to hardening process We should get the Initial dimension of the gear

MicrostructureChemical compositionHardness test

Dimentional Measurement

Before Induction Hardening Process

After Induction Hardening Process

Dimentional MeasurementMacro test

Hardness testMicrostructure

Laboratory of tribology UNDIP 2016

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ADDENDUM CIRCLE DIAMETER

MEASUREMENT EQUIPMENT

TOOTH THICKNESS

Laboratory of metrology ATMI Surakarta 2016

Laboratory of metrology training center UNDIP Semarang 2016

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Get Average Value From 2 Times Measurement

ADDENDUM CIRC DIAM and DED CIRC DIAM (CMM)

Laboratory of metrology ATMI Surakarta

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FIRST MEASUREMENT TO TOOTH HIGHT START FROM PITCH CIRCLE LINE

Laboratory Training Center UNDIP 2016

TOOTH THICKNESS

Get Average Value From 2 Times Measurement

UNTIL RIGHT SIDE

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Uji Makro

Hasil Makro

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MACRO TEST USE OPTICAL MICROSCOPI TYPE USB

Laboratory Training Center UNDIP 2016

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SPESIFICATION OF GEARS

TABLE 1. Geometrical parameters of gears

Item Gear A

With temperature 820OC

Gear B With temperature

880OC

Gear C With temperature

920OC Number of Teeth 29 29 29 Module 1.75 1.75 1.75 Pitch diameter (mm) 52.551 52.552 52.529 Face width (mm) 8 8 8 Bore diameter (mm) 20 20 20 Tooth Depth (mm) 3. 852 3.828 3.836 Pressure Angle (0) 20 20 20 Addendum Circle Diameter (mm) 56.363 56.377 56.397 Tooth Thickness (mm) 2.730 2.731 2.737

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RESULTS

Chemical composition of the alloys

Alloy Fe C Si Mn P Cr Ni Mo Cu Al V W

Tested Gear 98.15 0.41 0.18 0.63 0.10 0.32 0.01 0.01 0.03 0.01 0.01 0.10

The tested gear is plain carbon steel and low alloy steel

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RESULTS

Microstructure on tested gear before Surface hardening (S45C Steel)

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RESULTSResults of hardening layer thickness and microstructure phase.

RESULTSHardness Distribution on the Surface of Gears shows that The hardness of the surface is higher than the depth area.

This happens because the higher of temperature and the longer of the heating time to resulting even the propagation of heating in the austenite phase. After the rapid cooling process, the austenite phase is transformed into martensite phase which is very hard and brittle.

RESULTS

Results of gear distortion such as all teeth for the tooth thickness average to be shrinkage and expansion. The highest value of shrinkage is 1.593% and the highest value of expansion is 1.396% at the temperature austenite is 820OC

DISTORTION ON THE TOOTH THICKNES FOR GEAR A

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RESULTS

DISTORTION ON THE TOOTH THICKNES FOR GEAR B

At the temperature 880OC was produced the types of distortion is shrinkage and expansion, the highest value of shrinkage is 0.835% and the highest value of expansion is 1.065%.

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RESULTSDISTORTION ON THE TOOTH THICKNES FOR

GEAR C

Heating temperature 920OC was produced type’s distortion are shrinkage and expansion. The highest value of shrinkage is 0.948% at the tooth number 26 and the highest value of expansion is 2.404% at the tooth number 23.

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RESULTS

DISTORTION ON THE ADDENDUM CIRCLE DIAMETER FOR GEAR A

The results of gear distortion such as all teeth for the addendum circle diameter average to be shrinkage.The highest value of shrinkage is 0.228%

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RESULTSDISTORTION ON ADDENDUM CIRCLE DIAMETER FOR

GEAR BDistortion on the addendum circle diameter average to be shrinkage and expansion. The highest value of shrinkage is 0.147% and the highest value of expansion is 0.059% at the temperature austenite is 820OC

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RESULTSDISTORTION ON THE ADDENDUM CIRCLE DIAMETER FOR

GEAR CAt the temperature 920OC was produced type’s of distortion are shrinkage and expansion also. The highest value of shrinkage is 0.099% and the highest value of expansion is 0.284%

CONCLUSION

The highest shrinkage of tooth thickness will also affect to contact angle because the size of gear tolerance is not standardized

Distortion of induction hardening gear is very high with a value of 2.404% (0.065 mm) heating by temperature 920OC, while for this highest value of distortion will influence to high precision at the tooth contact is not appropriate.

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REFERENCE

1. Jozef Wojnarowski and Valentin Onishchenko (2003), “Tooth wear effects on spur gear dynamics”. Pergamon; Mechanism and Machine Theory 38, 161–178.2. Valentin Onishchenko (2015), “Investigation of tooth wears from scuffing of heavy duty machine spur gears ” , Elsevier, Mechanism and Machine Theory 83, 38–55.3. A. Sugianto, M. Narazaki, M. Kogawara, S.Y. Kim, and S. Kubota, Distortion Mechanism During Carburising-Quenching of SCr420H Helical Gear, Proc. 16th IFHTSE Congress, Oct 30-Nov 1, 2007 (Brisbane), Materials Australia, 2007, IFHTSE07-257.4. A.K. Rakhit, Heat Treatment of Gears, ASM International, Materials Park, OH, 2000, p 91–100.5. Coupard D, Palin-luc T, Bristiel P, Ji V, Dumas C. Residual stresses in surface induction hardening of steels: Comparison between experiment and simulation. Materials Science and Engineering A. 2008; 487:328-39.6. Joseph E. Sighley, Standard handbook of machine design, Third edit., vol. 17, no. 3. United States of America, 1996.