TO REDUCE VARIATION IN INDUCTION HARDENING

INTRODUCTION
Hardening uses heat and rapid cooling (quenching) to increase the hardness, strength and/or
durability of steel. Heating steel or iron above their upper critical temperatures modifies the
crystal structure of the metal to a form called Austenite. With this atomic arrangement the carbon
can then freely migrate to a new location. When hardening, the aim is to quickly quench the
Austenite, thus trapping the carbon atoms in their new positions in the crystalline structure. The
transformed structure, called Martensite, is extremely hard. In addition, hardening creates
important internal residual stresses that can be either beneficial or disadvantageous. Depending
on requirements, tempering can be carried out after the induction hardening process.
With induction hardening, only the material in the heating zone is heated. Theres no need to
treat the whole mass of the component, thus saving energy. The hardening result depends upon a
complex interaction of process parameters such as coil and quench design, material analysis,
component geometry, heating frequency and power and quenching cycles. At EFD Induction we
have all the expertise required in electromagnetism, power electronics, metallurgy and induction
hardening process setup. Induction has been developing induction-heating solutions for more
than 50 years. Today, were the worlds largest induction hardening equipment maker, with
manufacturing plants, R&D centers and sales companies around the world. Our strength is
complete, tailored systems. We usually start in the lab, with materials analysis and computerized
simulation of various solutions. We also look at coil design, and determine which quenching,
loading/unloading and control systems best suit your needs. And of course, we dont consider our
job done until your systems and your operators are up and running 100%.
Hard-line is our complete range of heat treatment systems from vertical, horizontal, rotary table
and center less systems to customized, one-off solutions. In fact, custom-engineered solutions
account for more than half of all the hardening systems we deliver.

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Major components in our systems are EFD Induction Sinac Universal Heat Generators. Sinac is
the markets widest range of generators, offering an unrivalled spectrum of frequencies. And of
course, we also offer tempering options, either as stand-alone options, or fully integrated into the
equipment.
The principle of induction heating by RF electric current, there an electric conductor such
as iron or steel placed in the inductor is heated rapidly by induced eddy current caused by
electromagnetic induction, and hysteretic heat loss, which is generated by vibration and friction
of each molecule in magnetic material under AC magnetic flux.
As RF frequency, which is higher than that of commercial electric power, is used for
induction heating, induced current flows only in the limited area near surface of heated material
because of skin effect and proximity effect, and heat loss occurs only there by eddy current and
hysteretic loss. The skin effect is the phenomenon, which RF electric current flows only in the
limited area near surface of conductive material, and proximity effect is the phenomenon, which
the primary current in the inductor and the secondary current in the conductive material pull each
other because the direction of current is opposite each other, and flows in the limited area near
surface where distance is nearest each other. The relation between frequency and depth of RF
electric current flow for steel material heated by induction at 1,000 degree. The depth depends
upon the frequency and as the frequency is higher, the depth becomes smaller as shown in the
curve.
Induction method of heating is wide spread used in numerous technological processes for
hot forming, surface hardening, annealing, etc. It is extremely effective because of its contactless
energy transfer, unlimited power densities and controlled temperature field in the work piece.
However, high potential of induction heating can be fully realized on the basis of numerical
simulation only. All technological processes used induction method of heating is multi physical.
Heating by induction it includes electromagnetic and thermal physics, which are strongly
coupled because of temperature dependent properties of the work piece material. Induction
heating is a process which is used to bond, harden or soften metals or other conductive materials.
For many modern manufacturing processes, induction heating offers an attractive combination of
speed, consistency and control.

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Many industries have benefited from this new breakthrough by implementing induction heating
for furnacing, quenching and [Link] principle of induction heating by RF electric current is
there an electric conductor such as iron or steel placed in the inductor is heated rapidly by
induced eddy current caused by electromagnetic induction, and hysteretic heat loss, which is
generated by vibration and friction of each molecule in magnetic material under AC magnetic
flux. As RF frequency, which is higher than that of commercial electric power, is used for
induction heating, induced current flows only in the limited area near surface of heated material
because of skin effect and proximity effect, and heat loss occurs only there by eddy current and
hysteretic loss. The skin effect is the phenomenon, which RF electric current flows only in the
limited area near surface of conductive material, and proximity effect is the phenomenon, which
the primary current in the inductor and the secondary current in the conductive material pull each
other because the direction of current is opposite each other, and flows in the limited area near
surface where distance is nearest each other.

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COMPANY PROFILE
NAME OF COMPANY:- GKN SINTER METAL [Link].
TYPE:- Public limited company
ADDRESS:-No.146,Mumbai-PuneRoad,Pimpri Colony,Pimpri-Chinchwad,Maharashtra-411018
TRADED AS LSE: GKN
INDUSTRY:-Automotive, Aerospace
ESTABLISHED:- 1975 Pimpri Plant
PRODUCTS:-Vehicle components (Powder Metallurgy)
REVENUE: - 7,231 million (2015)
OPERATING INCOME:- 323 million (2015)
NET INCOME:- 202 million (2015)
NUMBER OF EMPLOYEES:- 600 (2016)
DIVISIONS: - GKN Powder Metallurgy,GKN Driveline,GKN Aerospace,GKN Land Systems,
WEBSITE:- [Link]

HISTORY
GKN SINTER METAL is a British multinational automotive and aerospace components
company headquartered in Redditch, Worcestershire. The company was formerly known as
Guest, Keen and Nettlefolds and can trace its origins back to 1759 and the birth of the Industrial
[Link] is listed on the London Stock Exchange and is a constituent of the FTSE 100
Index. Dowlais Ironworks by George Childs (1840) The origins of GKN lie in the founding of
the Dowlais Ironworks in the village of Dowlais, Merthyr Tydfil, Wales, by Thomas Lewis and
Isaac Wilkinson. John Guest was appointed manager of the works in 1767, having moved from
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[Link] 1786, John Guest was succeeded by his son, Thomas Guest, who formed the Dowlais
Iron Company with his son-in-law William Taitt. Guest introduced many innovations and the
works prospered.
Under Guest's leadership, alongside his manager John Evans, the Dowlais Ironworks gained
the reputation of being "one of the World's great industrial concerns".Though the Bessemer
process was licensed in 1856, nine years of detailed planning and project management were
needed before the first steel was produced. The company thrived with its new cost-effective
production methods, forming alliances with the Consett Iron Company and [Link] 1857 G.T.
Clark and William Menelaus, his manager, had constructed the "Goat Mill", the world's most
powerful rolling mill.
By the mid-1860s, Clark's reforms had borne fruit in renewed profitability. Clark delegated
day-to-day management to Menelaus, his trusteeship terminating in 1864 when ownership passed
to Sir Ivor Guest. However, Clark continued to direct policy, in particular, building a new plant at
the docks at Cardiff and vetoing a joint-stock company. He formally retired in 1897.
On 9 July 1900, the Dowlais Iron Company and Arthur Keen's Patent Nut and Bolt
Company merged to form Guest, Keen & Co. Ltd. Nettlefolds Limited, a leading manufacturer
of fasteners, had been established in Smethwick, West Midlands, in 1854 and was acquired in
1902 leading to the change of name to Guest, Keen and Nettlefolds - (GKN).
Steel production remained at the core of the company, but under increasing profit margin
pressure. Resultantly in 1930, the company amalgamated its steel production business with that
of rival Baldwins to form Guest Keen Baldwins, which now held
Baldwins: Coke ovens at Margay; Blast-furnaces and steel melting shop at Margam; steel works
and rolling mills at Port Talbot; blast-furnaces at Briton Ferry; lime stone quarry at Cornell
GKN: Dowlais Iron and Steel Works; Cardiff Iron and Steel Works; coke ovens at Cwmbran;
limestone and silica quarries In 1935 the company demolished the Cardiff works to construct a
new modern production facility on the same site, funded by an issue of debentures. Due to a
resultant global shortage of pig iron, in 1937 the company fired-up the single remaining blast
furnace at [Link] of the sites were heavily bombed by the Nazi Luftwaffe during the war,
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and the required investment meant that all of these assets were nationalized as part of the 1951
Iron and Steel Act, resultantly becoming part of the Iron and Steel Corporation of Great Britain.
However, GKN were still highly reliant on the supply of good quality steel, and so in 1954
negotiated from the asset realization company the repurchase of key assets from ISC, which were
renamed Guest Keen Iron and Steel Co. In 1961 the company's name changed again to GKN
Steel Company

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THE COMPANY IS ORGANIZED AS FOLLOWS:
1. GKN Aerospace

Aero structures

Engine Products

Propulsion Systems

2. GKN Driveline

Driveshaft

Freight Services

3. Auto structures

Cylinder liners, Sheep bridge Stokes

GKN Land Systems

4. Power Management

Power Train Systems & Services

Wheels and Structures

Struma

5. GKN Powder Metallurgy

Sinter Metals

Hoeganaes

References

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OPERATIONS
Hydrogen Storage
Hydrogen is emerging as an important energy vector and as a true zero-emission fuel if produced
with renewable [Link] is developing an innovative hydrogen storage technology on
industrial scale. In this technology, hydrogen is stored with superior volumetric density and low
pressure. Special metal composites store hydrogen as metal hydrides like in a sponge, making
this technology very safe and providing a low storage footprint.
Technology & Innovation
Our people are driving innovation. We have a vision of whats to come advanced thinking
increased capacity and design freedom. We spark life changing technologies, such as additive
manufacturing, high performance gears and soft magnetic composites. In a process driven
business powered by innovation we are a one-stop solution provider.
High Performance Gears
As development partner of the automotive industry we are producing the widest range of sintered
high performance gears from metal powder worldwide. Our processes are environmental
friendly, producing safe and quit-running components with a long service life.
Soft Magnetic Composites (SMC)
SMC enables entirely new approaches in electric motor design such as axial or transverse flux
motors. By using PM technology, the limits in torque and power density can be expanded, thanks
to an increased freedom in part design and reduction of manufacturing costs.
Design for Powder Metallurgy
The powder metal industry, for the most part, has historically operated in a build to design
environment, because engineers often work sequentially: first a design is completed, and then a
manufacturing process is sought. This method inhibits product optimization by overlooking the
advantages that the collaborative Design for PM approach delivers
Powder To Part: Material Manufacture
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Powder metal components are becoming more prevalent in automotive and other applications.
GKN recycles scrap steel to manufacture the materials that make these parts
PRODUCTS (PIMPRI PLANT):1. CLUTCH HUBS

Overview

Clutch hubs are high strength products that are attached to the clutch plate and used to transmit
engine output torque into the transmission. PM has proven to be an ideal and competitive
solution for this application due to a combination of net shape capability and excellent material
performance.

Application Details

Manual transmissions
Automotive and light truck

Advantages

Supplied net shape and hardened: Ready to Install

Designs optimized for ease of attachment to clutch plate
Reliable, repeatable and low distortion sinter-hardening process eliminates separate hardening
step

Material: Steel

Process: Conventional PM

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Fig:- Clutch Hubs

2. ONE WAY CLUTCHES

Overview

One way clutches (OWC) are a key component of all automatic transmissions. PMs design
freedom combined with dimensional precision, and high performance materials facilitated the
development of new OWC systems that are more easily integrated into compact and efficient
transmission designs.
GKN is the market leader for PM OWCs with an established track record of delivering
optimized and competitive solutions for many customers and applications.

Application Details

Automatic transmissions for front and rear driven vehicles

Automotive and light truck applications

Advantages

Lightweight optimized designs

Net shape capability and consistent dimensional precision reliably delivers complex geometry
with minimal machining

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Consistent, low distortion sinter hardening process eliminates variation inherent to competing
hardening processes
Option to integrate OWC into other components such as planetary carriers

Material: Steel

Process: Conventional PM

Fig:- One way clutches

3. PLANETARY CARRIERS

Overview

Planetary carriers are a key component of automatic transmissions. As the demand increased for
more fuel efficient vehicles with transmissions with more forward speeds, planetary carriers
became more complex and also began to serve multiple functions. PM technology has delivered
an essential solution by facilitating the integration of carrier housings with one way clutches,
hydraulic pressure systems and clutch backing plates resulting in unprecedented savings in
weight, space, and cost vs. competing technologies.

Application Details

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Automatic, continuously variable, and hybrid transmissions
Passenger car and light truck applications
Supplied as blanks, finish machined carriers, or assemblies

Advantages

Design freedom facilitates unique designs and integrated functions

Lightweight, high strength designs
Sinterbonding reliably joins multiple levels and different materials
Minimal machining required due to nearest to net shape capability
Pinion gear contact surfaces are net shape and include geometry to optimize lubrication

Material: Steel

Process: Conventional PM

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Fig:-Planetary carriers

4. SYNCHRONIZER HUBS

Overview

Synchronizer Hubs are the core product for the shifting mechanism in all double clutch and
manual transmissions. PM has proven to be the premier solution for this component, and has
facilitated improvements in performance while also reducing weight. GKN has a proven track
record of developing optimized and competitive solutions for many different customers and
applications on a global basis.

Application Details

Double clutch and manual transmissions

Automotive and light truck applications
Solutions for both highly competitive and high performance applications
Torque levels up to 750Nm

Advantages

Lightweight, optimized designs with integrated features to improve performance and lubricant
distribution
Excellent dimensional precision for improved shift feel
Minimal machining is required due to nearest to net shape capability
Materials matched to performance requirements
In-house fatigue performance testing
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Global capability: manufactured in three regions

Material: Steel

Process: Conventional PM

Fig:-Synchronizer Hubs

5. TURBINE HUBS

Overview

Automatic transmissions rely on a torque converter to engage and disengage engine power
without the need for a driver-operated clutch. The main part of a torque converter is a fluid
turbine which selectively transfers engine power into the transmission. A turbine hub is the
coupling that connects the engine to the torque converter. PM technology has proven to be an
highly competitive and high performance solution for many customers and applications.

Application Details

Automatic transmissions with wet clutch torque converter

Front and rear wheel drive transmissions
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Automotive and light truck applications

Advantages

Nearest to net shape solution only minimal machining required

Optimized oil flow geometry - with no sharp edges or loose burr risks
Proven, high strength materials

Material: Steel

Process: Conventional P/M

Fig:-Turbine hub

6. INDUSTRIAL COMPONENTS
Bicycle Hub Transmission Bicycle Hub Transmission
Components for bicycles provide a great variety of applicability for Powder Metallurgy, for
example in gear hub components. PM can be implemented for all components that are exposed to
high stress.
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7. MEDICAL COMPONENTS
The rapidly growing sophistication of the medical field is driving the need for surgical tooling
and laboratory equipment as well as prosthetic implants, and artificial limbs. These products
require highly complex geometries and high performance materials that deliver corrosion
resistance and strength.
8. FASTENERS
Display showing products of Guest Keen & Nettlefold Ltd. in decorative form.
These mergers heralded half a century in which the name GKN became synonymous with the
manufacture of screws, nuts, bolts and other fasteners[according to whom?. The company
reflected the vertical integration fashionable at the time embracing activities from coal and ore
extraction, and iron and steel making to manufacturing finished goods.
9. CRANKSHAFTS
After the First World War it became apparent that Britain was likely to follow France and more
recently the United States in developing a large scale [Link] acquired another
fastener manufacturer, F. W. Cotterill Ltd., in 1919: Cotterill already owned a subsidiary named
J. W. Garrington, which specialised in forgings, and it was the forgings produced at the
Garrington Darlaston plant, later supplemented by a large plant at Bromsgrove, that enabled
GKN to become a major supplier of crankshafts, connecting rods, half-shafts and numerous
smaller forged components to the UK auto-industry during and beyond the period of massive
expansion between the two world wars.
10. PRESSED STEEL WHEELS
In 1920, GKN purchased steel company John Lysaght and their subsidiary, Joseph Sankey and
Sons Ltd. After training as an engineer, Sankey founded a major tea tray producer. A pioneer
motorist, he became personal friends with Herbert Austin, resultantly becoming a supplier of
sheet steel components to the industry. By 1914, the company's customers for sheet steel bodies
included Austin, Daimler, Humber, Rover, Star and [Link] a result of complaints from motor
manufacturers about the propensity of the then wooden wheels on early cars to disintegrate on
the slightest encounter with any roadside kerb,using his experience from tea trays Sankey
developed an alternate pressed-steel [Link] started in 1908, with customers including
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Herbert Austin and, later, William Morris. In addition to his original factory at Bilston a new
plant was established near Wellington,

PROCESSES IN PIMPRI PLANT: PM Today

The majority of PM products are manufactured using the Conventional method pioneered in
the 1930s. Improvements in materials and processes has resulted in a new class of high
performance, consistent, competitive and creative product. READ MORE
Soft Magnetic PM
Growing demand for electric motors and electro-mechanical systems has highlighted a need for
new design and material solutions. PM technology and new soft magnetic materials enable
engineers to develop smaller products with improved performance. READ MORE
Aluminum PM
New PM Aluminum materials developed by GKN are challenging paradigms about material
performance offering a new option to engineers when weight reduction and performance
improvement are priorities. READ MORE
Surface Dandified PM
A new PM technology that enables high density performance where required, without the weight
penalty of fully dense products. This is an ideal process for complex, highly stressed gears
requiring high performance and light weight. READ MORE
Porous Metal Filters
Filters and associated components based on GKNs controlled porosity materials are depended
on in a wide variety of demanding applications where traditional filters are unable to deliver the
required performance. READ MORE
Metal Injection Molding

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Delivering the three dimensional shape capability of plastic injection molding combined with the
performance of alloy steels, stainless steels and high temperature alloys, MIM is uniquely
positioned to solve extreme product challenges.

Materials
GKN Sinter Metals offers the broadest material selection in the industry to meet a wide range of
needs, including Aluminum, Alloy and Stainless Steel, Iron, Bronze, Brass, Composites and High
Temperature alloys.
Prototyping in AM
In a competitive environment, speed is a crucial enabler - getting your solution to the market first
is a clear advantage. GKN's additive manufacturing capabilities are allowing us and our partners
to develop products more rapidly.

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LITERATURE SURVEY
1. A Critical Review On Different Coil Configurations Used For Induction Heating System
By Tejas G. Patil1, Atul A. Patil2, Vijay H. Patil3 Department Of Mechanical
Engineering Godavari College Of Engineering, Jalgaon, India.
Induction heating system has a number of inherent benefits compared to
traditional heating systems due to a non-contact heating process. The main interesting
area of the induction heating process is the efficiency of the usage of energy, choice of
the plate material and different coil configurations based on application. Correctly
designed, manufactured and maintained induction coils are critical to the overall
efficiency of induction heating solutions. The important investment in induction heating
process is in highly qualified coil technicians and advanced coil design equipment and
got benefit by having coils that are customized to their specific needs and conditions, The
objective of the present work reviews different coil configurations used for the induction
heating Process which is based on application such as surface hardening, Casting,
Rolling, welding, Brazing, Bonding, Post Heating and Water Heating.
2. Development Of Induction Surface Hardening Process For Small Diameter Carbon Steel
By Specimens Daisuke Suzuki, Koji Yatsushiro, Seiji Shimizu (1), Yoshio Sugita (2),
Motoki Saito (3), Katsuhiko Kubota(1) Yamanashi Industrial Technology Center (2) Ys
Electronics Co., Ltd. (3) Asakawa Heat Treatment Co., Ltd. (4) Marushin Heat Treatment
Co., Ltd.
In case of induction hardening, the highly frequency generator make a shallow
hardened zone. Additionally, hardening for smaller diameter specimen is enabled. In this
study, the induction surface hardening process by the ultra high frequency generator of
2MHz, which had not used in the general conventional process, was developed. The
specimen (6mm in diameter) was hardened using our developed device, under various
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conditions of generator voltage and specimen moving speed. Quenched specimens were
evaluated by measuring residual stress distribution, cross-section observation, hardness
distribution and distortion. As a result, one of heat treatment condition brought a good
result; the depth of hardened zone was about 0.4mm, and the hardness was about 600HV
near the surface. The deeper hardened zone specimens had compressive residual stress
about
500MPa in the longitudinal direction at the surface. Moreover, it was decreased
slightly from surface to center. However, in the hoop direction, compressive residual
stress was about 0MPa. This anisotropy was caused large thermal stress, which was
compared with the present induction hardening. Furthermore, the best result in 3mm
diameter specimen had very shallow hardened zone that depth was about 0.09mm, and
hardness was about 600HV near the surface.
3. Optimization of processing parameters in induction hardening using response surface
methodology

ByAMIT KOHLIa, and HARI SINGHbaMechanical Engineering

Department, DAV Institute of Engineering and Technology, Kabir Nagar, Jalandhar City,
Punjab 144 008, India bMechanical Engineering Department, National Institute of
Technology, Kurukshetra 136 119, India email: mechanical_amit@[Link];
hsingh_nitk@[Link].
In this paper, an effective procedure of response surface methodology (RSM) has
been utilized for nding the optimal values of process parameters while induction
hardening of AISI 1040 under two different conditions of the material i.e., rolled and
normalized. Various process parameters, such as feed rate (speed at which the induction
coil moves, which is measured in mm/sec), current, dwell time (time after which heat
intensity starts to heat work piece in seconds) and gap between the work piece and
induction coil have been explored by experiments. Hardness at two different conditions
has been considered as performance characteristic. The experi- ment plan was based on
rotatable, central composite design (CCD). The experimental results showed that the
proposed mathematical models suggested could describe the performance indicators
within the limits of the factors being investigated. The obtained optimal process
parameters have been predicted and veried by conrma- tion experiments.

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Microstructure and SEM (scanning electron microscope) analyses were also done for
justication of the work.
4. Effects of induction heating process parameters on hardness profile of 4340 steel bearing
shoulder using 2D axisymmetric [Link] Habib Hammi, Noureddine Barka,
Abderrazak El Ouafi, Mathematics, Computer and Engineering Department, University
of Quebec at Rimouski Rimouski, Quebec, Canada..
The main of this work is to study the effects of machine parameters (Heating
system) on 4340 bearing seating shoulder heated by induction process. This process is
able to produce uniform hardness profile with compressive residual stresses favorable to
prevent fatigue contact failure. This paper presents, first, 2D axisymmetric model
developed by multi-physics commercial software. This model is used to analyze
quantitatively the effects of machine parameters such as imposed current density, heating
time, frequency, and some dimensional factors related to the part dimensions. The
simulation results are advantageously exploited to quantify the effects of the parameters
and the interactions between them. Finally, a sensitivity study is done to predict the
temperatures and to create a model to follow. The obtained results are very beneficial to
develop other geometries with the same approach.
5. Shailesh S.Pachbhai1, Laukik P.Raut2[1],In machining fixtures, minimizing workpiece
deformation due to clamping and cutting forces is essentialto maintain the machining
accuracy.
The various methodology used for clamping operation used in different
application by various authors are reviewed in this paper. Fixture is required in various
industries according to their application. This can be achieved by selecting the optimal
location of fixturing elements such as locators and clamps. The fixture set up for
component is donemanually. For that more cycle time required for loading and unloading
the material. So, there is need to develop system which canhelp in improving productivity
and time. Fixtures reduce operation time and increases productivity and high quality of
operation [Link] efficiency and reliability of the fixture design has enhanced by
the system and the result of the fixture designhas made more reasonable. To reduce cycle
time required for loading and unloading of part, this approach is useful. Ifmodern CAE,
CAD are used in designing the systems then significant improvement can be assured. To
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fulfill the multifunctional and high performance fixturing requirements optimum design
approach can be used to provide comprehensive analyses and determine an overall
optimal design. Fixture layout and dynamic clamping forces optimization method based
on optimal fixture layout could minimize the deformation and uniform the deformation
most effectively .The proposed fixture will fulfilled researcher production target and
enhanced the efficiency, Hydraulic fixture reduces operation time and increases
productivity, high quality of operation, reduce accidents.

6. [Link] Rudnev[2],Induction hardening is a heat treating technique that canbe used to

selectively harden portions of a gear, such as the flanks, roots and tips of teeth, providing
improved hardness, wear resistance and contact fatigue strength without affecting the
metallurgy of the core and other parts of the component that dont require change.
This article provides an overview of the process and special considerations for
heat treating gears. Part I, which was published in the September/October 2008 issue,
covered gear materials, desired microstructure, coil design and tooth-by-tooth induction
hardening. Part II covers spin hardening and various heating concepts used with
[Link] hardening of gears includes a number of process concepts that can be applied
depending on the part geometry and hardness profile required. Spin hardening
techniques, wherein the coil encircles the part, are most often used for small and medium
size gears.
7. Amit Kohli and Hari Singh[3], An effective procedure of response surface methodology
(RSM) has been utilized
In this paper for finding optimal values of process parameters for mean effective
case depth in induction hardening of AISI 1040 in rolled condition. Various process
parameters such as feed rate, current, dwell time and gap between the work piece &
induction coil, are explored by experiments. The experimental plan was based on
rotatable central composite design (CCD). The experimental results show that the
proposed mathematical model could describe the performance indicator within the limits
of the factors being investigated. The optimal value for mean effective case depth
obtained was 3.09 mm at the optimal settings of the process variables. The results have
been verified by confirmation experiments The experimental investigation shows the
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effect of process parameters such as feed rate, dwell time, current, and gap between
material and inductor coil, on the mean effective case depth of induction hardened AISI
1040 steel. The optimal value for mean effective case depth obtained was 3.09 mm in
rolled condition of the material at feed rate of 2 mm/s, dwell time of 5 sec, current of 135
amperes and gap between material and inductor coil of 5.17 mm as optimum values of
process parameters

8. AMIT KOHLI and HARI SINGH(4), In this paper, an effective procedure of response
surface methodology (RSM) has been utilized for finding the optimal values of process
parameters while
induction hardening of AISI 1040 under two different conditions of the material
i.e., rolled and normalized. Various process parameters, such as feed rate (speed at which
the induction coil moves, which is measured in mm/sec), current, dwell time (time after
which heat intensity starts to heat work piece in seconds) and gap between the work piece
and induction coil have been explored by experiments. Hardness at two different
conditions has been considered as performance characteristic. The experiment plan was
based on rotatable, central composite design (CCD). The experimental results showed
that the proposed mathematical models suggested could describe the performance
indicators within the limits of the factors being investigated. The obtained optimal
process parameters have been predicted and verified by confirmation experiments.
Microstructure and SEM (scanning electron microscope) analyses were also done for
justification of the work
The experimental investigations have shown that the effect of process parameters such as
feed rate, dwell time, current and gap between material and inductor coil on the hardness of AISI
1040 steel under two different conditions i.e., rolled and normalized during induction hardening.
The optimal values for hardness obtained were 56.4 HRC and 57.8 HRC respectively for rolled
and normalized condition at feed rate of 3.21 mm/s, dwell time 5 sec, current 135 Amperes and
gap between material and inductor coil 5.29 mm as optimum value of process parameters. The
results tabulated in table 5 show that experimental data and data obtained by regression equation
closely correlate each other which validate the regression equations developed. Hence it can be
concluded that for making shafts, axles or automobile components from medium carbon steel,

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raw material should be first normalized and then induction hardened so that uniform hardness of
the material can be obtained.

9. P. G. Kochure and K. N. Nandurkar[5 ] Mathematical modeling with computer

application is becoming more and more popular in study, development of setup,
maintenance of induction heating process. It can be used to explain, demonstrate and
predict the process performance of induction hardening system. Different methods used
to solve the field problems.
In this paper, an effective Taguchi methodology has been utilized for selection of
optimum process parameters of induction hardening of EN8 D steel. Various parameters
such as power and heating time have been explored by experimentation. An orthogonal
array, L9 , analysis variance of ANOVA are applied study the performance characteristic
of induction hardening process. Hardness has been considered as performance
characteristic. Analysis of variance (ANOVA) of response variable shows a significant
influence of process variables i.e. power and heating time. The experimental results
shows that the predicted mathematical models suggested could describe the performance
characteristics within the limits of the factors being investigated .The results of regression
equations have been verified by confirmation tests. Also microstructure analysis is done
for justification of hardening work
Taguchi method of experimental design with L9 orthogonal array has been
applied for selection of optimum process parameters of induction hardening of EN8 D
steel. The experimental investigation shows the effects of process parameters such as
power, heating time on hardness and case depth pattern achieved on work piece. The
optimum parameters found are 14 kw power and heating time 4 sec. power is the most
influential parameter. Further multiple regression equations are formulated for estimating
predicted values of hardness of slots for a specified range. The results obtained by
regression equations closely co relate each other which validates the regression equation
developed. And micro structure analysis justified the hardening work.

10.

Dr. Zhichao (Charlie) Li[9], Contact fatigue and bending fatigue are two main failure
modes of steel gears, while surface pitting and spalling are two common contact fatigue

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failures caused by alternating subsurface shear stresses from the contact load between
two gear mates. And when a gear is in service under cyclic load, concentrated bending
stresses exist at the root fillet the main driver of bending fatigue failures. Induction
hardening is becoming an increasingly popular response to these problems, due to its
process consistency, reduced energy consumption, clean environment and improved
product quality but not without issues of its own (irregular residual stresses)
An innovative approach of pre-heating prior to the induction hardening process is
proved to be effective in enhancing the residual compressive stresses at the root fillet of
gear components, which benefits the bending fatigue performance. Uniform pre-heating
temperature by furnace is assumed in this paper, but induction heating with lower
frequency and lower power inductor can also be used to preheat the opposite side of gear
teeth. The temperature distribution at the end of pre-heating doesnt need to be uniform.
With different gear geometry, steel grade and service condition, different inductor designs
and pre-heating processes could be designed to enhance the residual compression at
critical regions
11. [Link] RUDNEV[10], Over the years, gear manufacturers have gained knowledge
about how technology can be used to produce quality parts. The application of this
knowledge has resulted in quieter, lighter and lower cost gears that have an increased
load carrying capacity to handle higher speeds and torques while generating a minimum
amount of heat and noise. Gear performance characteristics (including load condition and
operating environment) dictate the required surface hardness, core hardness, hardness
profile, residual stress distribution, grade of steel and the prior microstructure of the steel.
In contrast to carburizing and nitriding, induction hardening does not require heating the
whole gear. With induction, heating can be localized to only those areas in which
metallurgical changes are required. For example, the fl anks, roots and tips of gear teeth
can be selectively hardened.
Induction hardening of gears is an important heat treating technique that can be
applied to a wide range of gears and other parts, especially internal and external spur,
helical and bevel gears, allowing manufacturers precise control over case depth and
microstructure for increased load carrying capacity and other properties. For best results
in induction hardening, manufacturers must ensure the proper initial condition of the gear
material, including chemical composition and microstructure. Tooth-by-tooth (tip-by-tip
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and gap-by-gap) methods are often used for larger gears. The methods were described,
along with various process and inductor design subtleties

1.3 Problem Definition

Part No

33362-0k050-00

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Gkn Part No -

34881

Part Name

Hub, Transmission Clutch, No.2

Customer

M/S Toyota Kirloskar Motors

Defect Details -

Uneven Induction Hardening, Case Depth 1 2mm Observed 0.41/0 &

0.70/0mm, Surface Hardness 600-800 Hv0.2mm Observed Less At Tap, Philippines

Date

30/07/2015

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1.4 Objective
1. To Reduce Uneven Induction Hardening.
2. Case Depth 1 2mm observed 0.41/0 & 0.70/0mm.
3. Develop New Design of Jig & Fixture.

Jig and Fixture

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The fixture is a special tool for holding a work piece in proper position during manufacturing
operation. For supporting and clamping the work piece, device is provided. Frequent checking,
positioning, individual marking and non-uniform quality in manufacturing process is eliminated
by fixture. This increase productivity and reduce operation time. Fixture is widely used in the
industry practical production because of feature and advantages.
To locate and immobilize work pieces for machining, inspection, assembly and other operations
fixtures are used. A fixture consists of a set of locators and clamps. Locators are used to
determine the position and orientation of a work piece, whereas clamps exert clamping forces so
that the work piece is pressed firmly against locators. Clamping has to be appropriately planned
at the stage of machining fixture design. The design of a fixture is a highly complex and
intuitive process, which require knowledge. Fixture design plays an important role at the setup
planning phase. Proper fixture design is crucial for developing product quality in different terms
of accuracy, surface finish and precision of the machined parts In existing design the fixture set
up is done manually, so the aim of this
project is to replace with hydraulic fixture to save time for loading and unloading of component.
Hydraulic fixture provides the manufacturer for flexibility in holding forces and to optimize
design for machine operation as well as process function ability.
Steps of fixture design
Successful fixture designs begin with a logical and systematic plan. With a complete analysis of
the fixture's functional requirements, very few design problems occur. When they do, chances are
some design requirements were forgotten or underestimated. The workpiece, processing, tooling
and available machine tools may affect the extent of planning needed. Preliminary analysis may
take from a few hours up to several days for more complicated fixture designs. Fixture design is
a fivestep problem-solving process. The following is a detailed analysis of each step.

Step 1: Define Requirements

To initiate the fixture-design process, clearly state the problem to be solved or needs to be met.
State these requirements as broadly as possible, but specifically enough to define the scope of the
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design project. The designer should ask some basic questions: Is the new tooling required for
first-time production or to improve existing production?
Step 2: Gather/Analyze Information
Collect all relevant data and assemble it for evaluation. The main sources of information are the
part print, process sheets, and machine specifications. Make sure that part documents and records
are current. For example, verify that the shop print is the current revision, and the processing
information is up-to-date. Check with the design department for pending part revisions. An
important part of the evaluation process is note taking. Complete, accurate notes allow designers
to record important information. With these notes, they should be able to fill in all items on the
"Checklist for Design Considerations." All ideas, thoughts, observations, and any other data
about the part or fixture are then available for later reference. It is always better to have too many
ideas about a particular design than too few. Four categories of design considerations need to be
taken into account at this time: workpiece specifications, operation variables, availability of
equipment, and personnel. These categories, while separately covered here, are actually
interdependent. Each is an integral part of the evaluation phase and must be thoroughly thought
out before beginning the fixture design.
Step 3: Develop Several Options
This phase of the fixture-design process requires the most creativity. A typical workpiece can be
located and clamped several different ways. The natural tendency is to think of one solution, then
develop and refine it while blocking out other, perhaps better solutions. A designer should
brainstorm for several good tooling alternatives, not just choose one path right away. During this
phase, the designer's goal should be adding options, not discarding them. In the interest of
economy, alternative designs should be developed only far enough to make sure they are feasible
and to do a cost estimate. The designer usually starts with at least three options: permanent,
modular, and general-purpose work holding. Each of these options has many clamping and
locating options of its own. The more standard locating and clamping devices that a designer is
familiar with, the more creative he can be. Areas for locating a part include flat exterior surfaces
(machined and unmachined), cylindrical and curved exterior surfaces. The exact procedure used
to construct the preliminary design sketches is not as important as the items sketched. Generally,
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the preliminary sketch should start should start with the part to be fixtured. The required locating.
and supporting elements, including a base, should be the next items added. Then sketch the
clamping devices. Finally, add the machine tool and cutting tools. Sketching these items together
helps identify any problem areas in the design of the complete fixture.
Step 4 : Implement the Design
The final phase of the fixture-design process consists of turning the chosen design approach into
reality. Final details are decided, final drawings are made, and the tooling is built and tested. The
following guidelines should be considered during the final-design process to make the fixture
less costly while improving its efficiency. These rules are a mix of practical considerations,
sound design practices, and common sense.
i. Use standard components:
The economies of standard parts apply to tooling components as well as to manufactured
products. Standard, readily available components include clamps, locators, supports, studs, nuts,
pins and a host of other elements. Most designers would never think of having the shop make cap
screws, bolts or nuts for a fixture. Likewise, no standard tooling components should be made inhouse. The first rule of economic design is: Never build any component you can buy.
Commercially available tooling components are manufactured in large quantities for much
greater economy. In most cases, the cost of buying a component is less than 20% of the cost of
making it.
Labor is usually the greatest cost element in the building of any fixture. Standard tooling
components are one way to cut labor costs. Browse through catalogs and magazines to find new
products and application ideas to make designs simpler and less expensive.
ii. Use prefinished materials:
Prefinished and preformed materials should be used where possible to lower costs and simplify
construction. These materials include precision-ground flat stock, drill rod, structural sections,
cast tooling sections,precast tooling bodies, tooling plates, and other standard preformed
materials. Including these materials in a design both reduces the design time and lowers the labor
cost.
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iii. Eliminate finishing operations:
Finishing operations should never be performed for cosmetic purposes. Making a fixture
look better often can double its cost. Here are a few suggestions to keep in mind with regard to
finishing operations.
iv. Keep tolerances as liberal as possible:
The most cost-effective tooling tolerance for a locator is approximately 30% to 50% of
the work pieces tolerance. Tighter tolerances normally add extra cost to the tooling with little
benefit to the process. Where necessary, tighter tolerances can be used, but tighter tolerances do
not necessarily result in a better fixture, only a more expensive one.
IMPORTANT CONSIDERATIONS WHILE DESIGNING JIGS AND FIXTURES.
Designing of jigs and fixtures depends upon so many factors. These factors are analyzed to get
design inputs for jigs and fixtures. The list of such factors is mentioned below :
a. Study of work piece and finished component size and geometry.
b. Type and capacity of the machine, its extent of automation.
c. Provision of locating devices in the machine.
d. Available clamping arrangements in the machine.
e. Available indexing devices, their accuracy.
f. Evaluation of variability in the performance results of the machine.
g. Rigidity and of the machine tool under consideration.
h. Study of ejecting devices, safety devices, etc.
i. Required level of the accuracy in the work and quality to be produced.

Methodology

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Forming

Sintering & Oil

Dipping

Sizing

Machining

Washing

Washing

Induction
Hardening

( Stansol 80 )

( Stansol 80 )

100% MPI & Oil

Dipping

100% Visual
Inspection

Dewatering

Packing

Dispatch

& Final RP Oil

Implementation On Valid Causes :1. Play in locating fixture

a) Locating fixture verified for any play,
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b)Impact on part verified Play observed in locating fixture as it is not a rigid , fixture is being
tightened with alen key & having a threaded shaft. There is chances of abnormal Induction
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hardening as like reported NG part in case of fixture not tighten completely or over tightened, as
there will be axis tilt or axis of locating fixture will not remain parallel to rotating spindle axis &
there can be abnormal rotation of fixture / locator.

2. Setting & Controllable Parameters tolerance NG Energy,

a) Setting & controllable parameters Verified

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b) All setting & controllable parameter s & their tolerance observed Ok except Energy, very
wide tolerance observed for energy ( 48 80 KJ ). Improvement required in setting of
energy band.

Modified IH Fixture, Rigid Fixture

3. .Uneven gap between part & coil as Heating coil & part gap setting method inadequate

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a) Simulation Trails Conducted in presence of TKAP Team by varying gaps between part coil.

fig:b) As per regular process gap of 0.9mm is being kept between part & coil. During simulation gap
increased by 0.8mm & 1.3mm than regular gap of 0.9mm. Parts observed at lower for case
depth for gap of 1.7 mm & observed NG for case depth ( Nill case depth ) for gap 2.2mm

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Fig:-

c) Heating coil & part gap setting method verified.

Modified Quenching Unit

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d) Operator set the fixture height & gap between part & coil with the help of setting master of
height more than 0.8mm than part boss height. The master is being placed on part locating
fixture & touches the coil to the top surface of master & by manual feeling he adjust the gap.
This cycle repeated for each station. Operator adjust the gap as per his experience & manual
feeling, there is no measurable method / system .Can be cause for Occurrence of defect.
However, gap setting by filler gauge is planned. New master is under manufacturing. This will
ensure further reduction in gap variation.

Fig:4. Parts inspection method inadequate

a) Part inspection method verified.
b) Only quarter section of the part is being checked for Case depth & CD, which is not adequate
method to know within the part variation.

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[Link] Frequency inadequate - First off / in process, Final

a) Inspection Frequency & records verified.
b) Only 1 part from all six station being checked for case depth during first off/ setting & 1 part
is being checked during shift during regular production as an in process inspection which is not
sufficient to identify variation during shift production.

Simulation Trails & Results For Validated Causes :[Link].

Trial

Change point
details

Qty

Observations Observations Status / Remarks

Produced of Parts -

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TO REDUCE VARIATION IN INDUCTION HARDENING

Visual
Change in

Case depth &

Coil Gap
( Trial
1

Cut Check

Hardness

Coil Gap Changed

Conducted to 2.20mm from 02 nos

Visually NG

in Presence 0.9mm

observed Less
.
CD Nill &

of TKAP

0.2mm

Team)
Gradual

Defective part could

simulated through the
Trail. Parts observed
with Nill Case depth
during the trail.

Change to
Coil Gap to
Confirm
6

the defined
standard
for coil gap
( 0.9mm )is

Defined Coil Gap

After this trail, It is

0.9mm,
Changed to
1)
2)
3)
4)
5)

1.1mm
1.3mm
1.5mm
0.7mm
0.5mm

06 Nos

Detailed

Detailed

concluded that

Report

Report

Defined Standard,

Attached

Attached

Gap of 0.9mm is

below

below

correct & gives good

result.

correct or
not
Trail is Pending due
5

Tilting the
Coil

Coil to be tilted &

to dispatch urgencies.

result to be

Unable to spare

compared.

machine and parts for

trials

Why Why Analysis & Root Cause Identification:Factor No. 7

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Play in Part Locating Fixture
WHY 1 No Diametrical Location provided / available to fix the locating shaft
WHY 2 Threaded shaft is given
WHY 3 To use the locating fixture for multiple parts
Root Cause - Non Detection
Threaded shaft is given to fixture without any diametrical location for alignment to use for
multiple parts

Factor No. 9
Variation in Gap Between Part & Coil in Six station
WHY 1 Gap setting method inadequate

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WHY 2 Gap is set by placing master on each locating fixture & touching the coil, operator
confirms the gap by manual feeling & based on experience
WHY 3 . No standard method / Measurable Method defined.
Root Cause - Occurrence
No standard method / Measurable Method defined to ensure correct gap between part & coil
at all Six stations.

Factor No. 11
Incorrect Checking Frequency
WHY 1 Only One part is being checked at First off & during shift for case depth & Hardness
which is not sufficient frequency to identify part to part & in process variation.
WHY 2 Checking Frequency Not defined correctly.

Root Cause - Non Detection

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Checking Frequency Not defined Correctly in Control Plan.

Factor No. 10
Part Inspection Method Inadequate
WHY 1 Only One Section / Quarter Section of Part is being cut & checked for case depth &
Hardness which is not sufficient to identify within part variation.
WHY 2 Checking method not defined correctly in Control Plan
Root Cause Non Detection

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Checking method not defined correctly in Control Plan

Factor No. 11
Incorrect Checking Frequency
WHY 1 Only One part is being checked at First off & during shift for case depth & Hardness
which is not sufficient frequency to identify part to part & in process variation.
WHY 2 Checking Frequency Not defined correctly.

Root Cause - Non Detection

Checking Frequency Not defined Correctly in Control Plan.

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Factor No. 10
Part Inspection Method Inadequate
WHY 1 Only One Section / Quarter Section of Part is being cut & checked for case depth &
Hardness which is not sufficient to identify within part variation.
WHY 2 Checking method not defined correctly in Control Plan
Root Cause Non Detection

Checking method not defined correctly in Control Plan

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Shedule :No

Actions

Target

Status

Part locating fixture to be made rigid to Locate the

11/08/2015

In

axis of rotating shaft & to use dedicatedly for

Process

Toyota Part.
2

Heating coil & Part Gap setting method to be

09/07/2015

Started

22/07/2015

In

modified, One station to be set with Setting Master

by touching coil to master, setting part to be
produced & checked for Case depth, Hardness &
soft zone, If part observes ok, height of other
stations to be set wrt to first station with the help
of dial indicator to reduce fixture to fixture
variation..
3

For further Improvement in setting, New setting

master to be made with size of part boss height &

Process

coil gap to be checked by filler gauge.

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4

Inspection of all six station parts for Case depth &

07/07/2015

Started

07/07/2015

Started

04/07/2015

Started

Hardness started during setting / first off at four

sections of single part, Previously only 1 parts was
being checked.
5

Inspection of three parts in shift started for case

depth & hardness respectively start, mid & end of
shift for regular production. With this method all
six station parts will be checked during a day i.e. in
Two shifts.

Part inspection method to be modified, Parts to be

cut in four sections & case depth & hardness to be
checked for all four sections, previously only one
section ( quarter section ) was been cut & checked.
This will be Continue till implementation of
Preventive actions.

100% Check added in Visual inspection.

03/07/2015

Started

For Effective controlling & monitoring of Energy,

03/07/2015

Started

22/07/2015

In

Setting of Energy Band in Machine Started,

Energy of all Six station parts to be recorded &
Band to set considering average reading Pus Minus
Three counts, same to be updated in setting
standard.
9

For further effectiveness in Inspection, Feasibility

to be checked for use of Eddy Current method for

Process

100% inspection.
For Eddy current test proposal we have given the
ok and NG samples to Technofour .The trials shall
be taken on the coil and based on the trials they
will submit the quotation.

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PART DIAGRAM:-

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PROCESS SHEETS:SHEET 1:-

PART NAME : HARDNING CAP

MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100

Sr.
No

Description of

Tools

Operation
Jigs &
Fixture

Time in minutes

Clamp stock

Three jaw

M/c

Cutting

Tools

Tools

Lathe

Measuring Setting M/c

Instrument
-

Time

Total

Time Time

20

20

10

10

chuck

Facing Both side

Three jaw

to total length

chuck

Lathe

82mm

SIDDHANT COLLEGE OF ENGINEERING,PUNE

Facing

Vernier

tool

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TO REDUCE VARIATION IN INDUCTION HARDENING

Turning OD

Turning

53.5 mm through

tool

15

20

Vernier

20

20

Vernier

20

20

length

4.

5.

StepTurning OD

Centers

to 14.70mm

supports &

through length 7

carrier

StepTurning OD

Centers

to 38.5mm

supports &

through length

carrier

Lathe

Turning
tool

Lathe

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Turning
tool

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SHEET 2:-

PART NAME : HARDNING CAP

MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100

Sr.
No

Description of

Tools

Operation

Jigs &
Fixture
1

2.

Time in minutes

Groving OD to

Centers

7mm through

supports &

length 9

carrier

Chamfring

Centers

2.5mm

supports &

M/c

Cutting

Tools

Tools

Lathe

Turning

Measuring Setting M/c

Instrument

Time

Total

Time Time

Vernier

20

20

Vernier

20

20

tool

Lathe

Turning
tool

carrier

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SHEET NO 3:-

PART NAME : HARDNING CAP

MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100

Sr.
No

Description of

Tools

Operation

Jigs &
Fixture
1

2.

Time in minutes

StepTurning OD

Centers

to 28mm

supports &

through length12

carrier

Turning OD

Centers

18.5 mm through

supports &

length 50mm

carrier

M/c

Cutting

Tools

Tools

Lathe

Turning

Measuring Setting M/c

Instrument

Time

Total

Time Time

Vernier

22

22

Vernier

30

30

tool

Lathe

Turning
tool

SHEET NO 4:-

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MATERIAL SPECIFICATION : MS

PART NAME : HARDNING CAP

RAW MATERIAL SIZE: 60X 100

Sr.
No

Description of

Tools

Operation

Jigs &
Fixture

Time in minutes

Clamp stock

M/c

Cutting

Tools

Tools

Three jaw

Drill

chuck

m/c

Drilling 4 holes 5

Centers

Drill

Drilling

mm

supports &

m/c

tool

Measuring Setting M/c

Instrument

Time

Total

Time Time

20

20

Vernier

10

10

Vernier

30

30

20

20

carrier
3

Drilling key hole

Centers

Drill

Turning

2mm

supports &

m/c

tool

carrier
4

Clamp stock

Three jaw

Lathe

chuck
SHEET NO 5:-

PART NAME : HARDNING CAP

MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100

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Sr.
No

Description of

Tools

Operation

Jigs &
Fixture
1

2.

Time in minutes

StepTurning OD

Centers

to 28mm

supports &

through length12

carrier

Turning OD

Centers

18.5 mm through

supports &

length 50mm

carrier

M/c

Cutting

Tools

Tools

Lathe

Turning

Measuring Setting M/c

Instrument

Time

Total

Time Time

Vernier

22

22

Vernier

30

30

tool

Lathe

Turning
tool

SHEET NO 6:-

PART NAME : BASE HUB

MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 75X 90

Sr.
No

Description of

Tools

Time in minutes

Operation

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TO REDUCE VARIATION IN INDUCTION HARDENING

Jigs &
Fixture
1

Clamp stock

Three jaw

M/c

Cutting

Tools

Tools

Lathe

Measuring Setting M/c

Instrument
-

Time

Total

Time Time

20

20

10

10

15

20

Vernier

20

20

Vernier

20

20

chuck
2

Facing Both side

Three jaw

to total length

chuck

Lathe

Vernier

tool

85mm
3

Facing

Turning OD 70

Turning

mm through

tool

length
4.

5.

StepTurning OD

Centers

to 50mm

supports &

through length 60

carrier

StepTurning OD

Centers

to 28 mm

supports &

through length

carrier

Lathe

Turning
tool

Lathe

Turning
tool

60mm

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TO REDUCE VARIATION IN INDUCTION HARDENING

SHEET NO 7:-

PART NAME : BASE HUB

MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100

Sr.
No

Description of

Tools

Operation

Jigs &
Fixture
1

Time in minutes

Clamp stock

M/c

Cutting

Tools

Tools

Three jaw

Drill

chuck

m/c

SIDDHANT COLLEGE OF ENGINEERING,PUNE

Measuring Setting M/c

Instrument
-

Time
20

Total

Time Time
-

20

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TO REDUCE VARIATION IN INDUCTION HARDENING

Drilling holes 18

Drill

Drilling

m/c

tool

Centers

Drill

Boring

supports &

m/c

tool

mm

Boring 0.5mm

Vernier

10

10

Vernier

carrier
4

Chamfring

Three jaw

Lathe

chuck
SHEET NO 8:-

PART NAME : BASE HUB

MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 70X90

Sr.
No

Description of

Tools

Operation

Jigs &
Fixture
1

Time in minutes

Drilling key hole

Centers

2mm

supports &

M/c

Cutting

Tools

Tools

Lathe

Turning

Measuring Setting M/c

Instrument
Vernier

Time
-

Total

Time Time
2

tool

carrier

SIDDHANT COLLEGE OF ENGINEERING,PUNE

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MODEL DIAGRAM:MODEL NO 1:- CAP

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TO REDUCE VARIATION IN INDUCTION HARDENING

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TO REDUCE VARIATION IN INDUCTION HARDENING

MODEL NO 2:- HUB

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TO REDUCE VARIATION IN INDUCTION HARDENING

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TO REDUCE VARIATION IN INDUCTION HARDENING

MODEL NO 3:- PIN

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TO REDUCE VARIATION IN INDUCTION HARDENING

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TO REDUCE VARIATION IN INDUCTION HARDENING

MODEL NO 4:-BOLT

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TO REDUCE VARIATION IN INDUCTION HARDENING

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TO REDUCE VARIATION IN INDUCTION HARDENING

MODEL NO 5:-ASSEMBLY

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TO REDUCE VARIATION IN INDUCTION HARDENING

COST ESTIMATIONS:-

SIDDHANT COLLEGE OF ENGINEERING,PUNE

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TO REDUCE VARIATION IN INDUCTION HARDENING

CONCLUSSION:-

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TO REDUCE VARIATION IN INDUCTION HARDENING

REFERENCE
[Link] kohli and Hari Singh (Received 2 Jan., 2010, Accepted 15 Feb., 2010) Optimizing mean
effective case depth of induction hardened parts(rolled condition) using response surface
methodology.
2. B. Kosec , B. Karpe , M. Licen and G. Kosec (Received 07.01.2010; published in revised form
01.04.2010) Inductive heating and quenching of planetary shafts.
3. Stanley Zinn and S. L. Semiatin -Coil design and fabrication: basic design and modifications.
4. P. G. Kochure and K. N. Nandurkar [Issue 2 (July-Aug 2012)] Mathematical modeling for
selection of process parameters in induction hardening of EN8 D steel.
5. V. Rudnev, D. Loveless, R. Cook and M. Black- Induction Hardening of Gears: a Review
6. Mert Onan, Kasim Baynal, [Link] Unal and Furkan Katre (November 9-15, 2012)
Optimization of Induction hardened AISI 1040 Steel by experimental Design Method and
Material Characterization Analysis.
[Link] S. Pachbhai and Laukik P. Raut(Feb-Mar 2014)A Review on Design of Fixtures.
[Link] G. Patil, Atul A. Patil, Vijay H. Patil A Critical review on different coil configurations
used for induction heating system.
9. Habib Hammi, Noureddine Barka and Abderrazak El Ouafi (7 jan 2015)Effects of Induction
heating process parameters on hardness profile of 4340 steel bearing shoulder using 2D
axisymmetric model
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10. Handbook of Design of Heating Coil of an Induction Heater/ Cooker
[Link] kohli and Hari Singh(25th feb 2011) Optimization of processing parameters in induction
hardening using response surface methodology.

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