Recently, one of our sales leads asked us to validate an induction hardening case by comparing the results of simulation versus real life, so their procurement team can make fact-based decisions. We decided to write an article based on this case to demonstrate the correlation between induction simulation and actual results.
Traditional ways of work simply aren't any more sustainable and effective, because the still ongoing technological revolution is reshaping all products and services that have been made before, giving place to new ones, even new concepts, and work titles.
Simulation is a good choice to find the best frequency to heat the step properly.
The Surface Impedance approach enables simulation of high frequency induction heating in few minutes, without building a huge mesh. Induced heat in a steel strip is accurately calculated in 10 minutes for 300 kHz, while traditional FEM simulation takes about 10 hours.
Heating of the 10 cm 45 teeth gear up to the austenitization temperature performed with overnight simulation, taking into account changes of magnetic properties over Curie temperature. You can get hardening profile without cutting the gear and optimise frequency within in a couple of days.
1h simulation allows to test performance of a new-designed coil virtually, saving time and money for building it.