The hardening and tempering treatment is a continuous and automated process controlled by Siemens PLC and friendly HMI. The induction heat treatment equipment is widely used to heat treating of the bars and tubes. Normally the hardening temperature is up to 950 ° C, followed by an abrupt cooling with water or other quenching media. A further heating at lower temperatures of tempering and a subsequent surface protection treatment and cooling follow this.
The temperature of the bars/pipes is constantly controlled by infrared thermometers located at the exit of each zone. The entire process can also be easily controlled and operated by an operator via touch panel and buttons. With induction heating technology, TY induction heat treatment line assures the maximum homogeneity of mechanical and structural prosperities both in the bar section and along in the bar length. Dimension range of bars that can be heat treated by the line is from 10 to 120mm diameter with length from 1.5 m to 7.0m. TY Induction's bar Hardening and tempering machine is fully automatic that ensure high production capacity up to 6t/h and over.
This line mainly consists of items such as Induction Power Supply and Inductor, Cooling System, Mechanical System, Automation and Temperature Measurement.
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M20 Induction Quenching and Tempering
Hardening and Tempering Equipment
Bar Hardening and Tempering Machine
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Heat Treatment Process Recipe
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Induction hardening uses induction heat and rapid cooling (quenching) to improve the hardness and durability of steel. Induction is a non-contact process that produces intense, localized and controlled heat quickly. By induction, only the part to be hardened is heated. Optimization of process parameters such as heating cycles, frequency, as well as coil and quench design gives the best results.
Induction hardening increases throughput. It is an extremely fast and repeatable process that can be easily integrated into a production line. It is clean, safe and usually has a small footprint. Workpieces are usually treated individually. This ensures that each individual workpiece is hardened to its own precise specifications. The optimized process parameters for each workpiece can be stored on your server. Induction hardening is very energy efficient because only the part to be hardened is partially heated.
Induction is used to harden many components. Examples include: gears, crankshafts, camshafts, drive shafts, output shafts, torsion bars, rocker arms, constant velocity universal joints, tulips, valves, rock drills, slewing bearings, inner and outer rings.
Hardening can be simply defined as any process in which the hardness of a material increases and the ductility decreases. This enhances high wear surfaces and extends the life of the part. Although there are many different methods of hardening, which may be more or less applicable depending on the material used, induction techniques are commonly used for the hardening process known as hardening and tempering.
Quenching and tempering is a hardening process that can only be performed in medium to high carbon steels. The steel is heated to a high enough temperature to change the crystal structure of the iron from ferrite to austenite. In this altered crystalline state, the steel is able to dissolve more carbon than would otherwise be the case. The steel is then quenched using water, oil or, in the case of induction equipment, a water-polymer solution. This quenching causes the steel to cool rapidly, thus preventing the formation of carbon deposits, which reduce the final hardness of the steel. Once the steel has cooled to a low enough temperature, the crystal structure tries to return to its low temperature state. At this point, the steel dissolves more carbon than it could hold in its original low-temperature state, so it transforms into a different crystal structure called martensite. Because of its distorted crystal structure and high carbon saturation, martensite is very hard. At this point, the steel is very hard, but also very brittle. Tempering involves heating the steel back to a much lower temperature to slightly reduce the hardness and therefore the brittleness. The temperature at which the steel is heated depends on how much hardness the steel needs to maintain. Once the desired hardness is achieved, the steel is quenched again to prevent further tempering of the steel by residual heat. Due to the distorted crystal structure and high carbon saturation, martensite is very hard. At this point, the steel is very hard, but also very brittle. Tempering involves heating the steel back to a much lower temperature to slightly reduce the hardness and thus the brittleness. The temperature at which the steel is heated depends on how much hardness the steel needs to maintain. Once the desired hardness is achieved, the steel is quenched again to prevent further tempering of the steel by residual heat. Due to the distorted crystal structure and high carbon saturation, martensite is very hard. At this point, the steel is very hard, but also very brittle. Tempering involves heating the steel back to a much lower temperature to slightly reduce the hardness and thus the brittleness. The temperature at which the steel is heated depends on how much hardness the steel needs to maintain. Once the desired hardness is achieved, the steel is quenched again to prevent further tempering of the steel by residual heat. The temperature at which the steel is heated depends on how much hardness the steel needs to retain. Once the desired hardness is achieved, the steel is quenched again to prevent further tempering of the steel by residual heat. The temperature at which the steel is heated depends on how much hardness the steel needs to retain. Once the desired hardness is achieved, the steel is quenched again to prevent further tempering of the steel by residual heat.
Induction technology is most commonly used in quenching and tempering procedures, and it offers the most obvious advantages. The procedure requires the steel to be heated and quenched very precisely to achieve the desired hardness distribution. Even very small variations in the process, such as heating for too long or quenching at the wrong temperature, can lead to large variations between parts. Therefore, precise control of the process becomes critical. Induction technology offers more control than any other heating method.
Automatic handling and fixing of heated and hardened parts provides high productivity and helps produce consistent results one after another. Induction is by far the fastest method of hardening and heat treatment. The result is a process that produces minimal distortion, no surface decarburization, fine grain microstructure and precisely controlled hardness patterns. Induction is the perfect solution for any facility looking to take production to the next level.
Selective induction surface hardening can improve part performance by providing a mix of mechanical properties, the hardness required for wear surfaces and the ductility of the core to provide impact resistance.
Selective induction hardening can specifically target localized areas of a part and heat it rapidly. As a result, the part forms a layer of hardened material or shell. This is ideal for parts that are subjected to high stresses in operation and require a combination of mechanical properties. For example, high yield strength with both fatigue and wear resistance.
The precise hardness pattern can be controlled by properly adjusting the frequency used, the induction coil geometry, the power level and the position of the part in the coil. Part-to-part hardness patterns remain highly consistent due to the industry-leading accuracy of the TY system. Rotation during the heating process ensures a uniform case.
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Secification
| Bar Diameter | 10mm to 120mm |
| Bar length | 1500mm to 7000mm |
| Hardening Temperature | 950℃ |
| Tempering Temperature | 650° |
| Maximum Production Rate | 6 t/h |
| Straightness | 0.004mm/m |
| Bar material | Carbon steels, special alloyed steel |
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Features
● Fast & Uniformly Heating
● High efficiency
● Less distortion
● Minimized oxidation skin
● Minimized decarburization
● Excellent homogeneity for quality right down to the core
● Low operating cost
● Energy-efficient production with low maintenance and servicing requirements
● Easy operation with automation
● Quick changeover and tooling
● Environmentally-friendly
● Good working condition for workers
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