Vestnik of Samara State Technical University. Technical Sciences SeriesVestnik of Samara State Technical University. Technical Sciences Series1991-85422712-8938Samara State Technical University10903810.14498/tech.2022.2.2Research ArticleProblem-oriented model of the technological process of surface induction hardeningPavlushinAleksey V.<p>Postgraduate Student</p>Alex1995i79@gmail.comhttps://orcid.org/0000-0003-1645-5803Samara State Technical University1608202230221342806202230062022Copyright © 2022, Samara State Technical University2022<p><em>The paper presents a nonlinear two-dimensional numerical model of the temperature and thermal stress fields within a steel billet of complex geometric shape in the surface induction hardening process. The problem-oriented model developed in the ANSYS Mechanical APDL software package can be integrated into the optimization procedure for designing an induction coil and controlling the heating and cooling stages. The following steps of modeling are described: setting the properties of materials, the geometry building and overlaying the FE mesh, setting the boundary conditions, and setting up the model calculation algorithm. To simulate the heating stage, the interrelated electromagnetic, thermal, and elastic-plastic problems are solved, which results in obtaining the spatio-temporal distributions of electromagnetic heat sources, temperature fields, and thermal stress fields over the workpiece volume. The model of the heating stage is oriented for further use in the numerical procedure of parametric optimization of the design and operating parameters of the induction installation to obtain the highest possible uniformity of the temperature distribution, on which the quality of the microstructure of the hardened layer depends significantly. To simulate the cooling stage, thermal and elastic-plastic problems are solved, providing the spatial-temporal distributions of temperature fields and thermal stresses over the workpiece volume. As a cooling (quenching) medium, a water shower is used after induction heating to form a martensitic microstructure of the surface hardened layer. The simulation of the cooling stage is performed using the temperature-dependent equivalent surface heat transfer coefficient, which greatly simplifies the modeling process. The model of the cooling stage can be integrated into the numerical procedure for solving the problem of optimal control of the spraying device, which allows for improving the hardening quality by adjusting the intensity of the water supply.</em></p>numerical simulationinduction heating stageintensive coolingsurface hardeningtemperature fieldthermal stressesANSYSчисленное моделированиеиндукционный нагревинтенсивное охлаждениеповерхностная закалкатемпературное полетермические напряженияANSYS[Pleshivtseva Y., Pavlushin A., Popov A. Optimal Design of Inductor Coils for Surface Hardening // 2022 International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM). – IEEE, 2022. Pp. 680–685.][Pavlushin A.V. Optimization of design and operating parameters of an induction heating installation for hardening // Bulletin of the Samara State Technical University. Series: Engineering sciences. 2021. V. 29. № 3(71). Pp. 38–51.][Arzamasov B.N. et al. 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Book Series: Lecture Notes in Electrical Engineering Editors:Prof. Andrey A. Radionov, Alexander S. Karandaev Publisher: Springer International Publishing Print ISBN: 978-3-030-39224-6. Electronic ISBN: 978-3-030-39225-3. Part of: Springer Professional Wirtschaft+Technik", Springer Professional "Technik".][Pleshivtseva Yu.E., Popov A.V., Popova M.A., Derevyanov M.Yu. Optimal design of an inductor for surface hardening of cylindrical blanks based on a numerical two-dimensional model // Bulletin of the Astrakhan State Technical University. Series: Management, Computer Engineering and Informatics. 2019. №. 1. Pp. 40–50.][Pleshivtseva Y., Baldan M., Popov A., Nikanorov A., Rapoport E., Nacke B. Effective methods for optimal design of induction coils on example of surface hardening, COMPEL. The international journal for computation and mathematics in electrical and electronic engineering, 2019, ISSN: 0332-1649, 39 (1). Pp. 90–99.][Korshikov S.E. 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