The document discusses research on the effect of temperature on distortion during induction surface hardening of gears. Three gears were induction hardened at different temperatures (820°C, 880°C, 920°C) and analyzed. Distortion was measured on tooth thickness and addendum circle diameter. The highest distortion values were 2.404% shrinkage on tooth thickness for the 920°C gear and 0.284% expansion on addendum circle for the same gear. Microstructure analysis found deeper martensite case depths with increasing temperature. Hardness also increased with depth from the surface.

1. 1
DEPARTMENT OF MECHANICAL ENGINEERING
DILI INSTITUTE OF TECHNOLOGY – TIMOR LESTE
RESEARCH
The Effect of Temperature Induction Surface
Hardening To the Distortion of Gear
NATALINO FONSECA D. S. GUTERRES

2. 2
CONCLUSION
REFERENC
ES
INTRODUCTION
EXPERIMENT
AL METHODS
RESULTS
AND
DISCUSSIONS

3. 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

4. 4
(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.

5. 5
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

6. 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.

7. 7
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
ExpansionContraction

8. 8
SPECIMENT GEARS
The study begins with the preparation of speciment such as three gears (self
manufactured), gear A for the temperature 8200
C, gear B for the temperature
8800
C and gear C for the temperature 9200
C
Gear A for the
temperature 8200
C,
48 kHz and 35 sec
Gear B for the
temperature 8800
C,
49 kHz and 45 sec
Gear C for the
temperature 9200
C,
50 kHz and 55 sec

9. 9
INDUCTION HARDENING PROCESS
Before going to hardening process We should get the Initial dimension of the gear
Microstructure
Chemical composition
Hardness test
Dimentional Measurement
Before Induction Hardening
Process
After Induction Hardening Process
Dimentional Measurement
Macro test
Hardness test
Microstructure
Laboratory of tribology UNDIP
2016

10. 10
ADDENDUM
CIRCLE
DIAMETER
MEASUREMENT EQUIPMENT
TOOTH
THICKNESS
Laboratory of metrology ATMI Surakarta
2016
Laboratory of metrology training center UNDIP Semarang 2016

11. 11
Get Average Value From 2 Times Measurement
ADDENDUM CIRC DIAM and DED CIRC DIAM (CMM)
Laboratory of metrology ATMI Surakarta

12. 12
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

13. 13
Uji Makro
Hasil Makro
1
2
MACRO TEST USE OPTICAL MICROSCOPI TYPE USB
Laboratory Training Center UNDIP 2016

14. 14
SPESIFICATION OF GEARS
TABLE 1. Geometrical parameters of gears
Item
Gear A
With temperature
820O
C
Gear B
With temperature
880O
C
Gear C
With temperature
920O
C
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

15. 15
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

16. 16
RESULTS
Microstructure on tested gear before Surface hardening (S45C Steel)

17. 17
RESULTS
Tested
gear
Gear location to macro
analysis
Microstructure analysis Types of
phase
Case depth
(mm)
Gear (A) at the
temperature
820O
C
Full
Martensite
7 mm
Gear (B) at the
temperature
880O
C
Martensite
+ perlite
9 mm
Gear (C) at the
temperature
920O
C
Martensite
+ perlite
13 mm
Results of hardening layer thickness and microstructure phase.

18. RESULTS
Hardness 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.

19. 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 820O
C
DISTORTION ON THE TOOTH THICKNES FOR
GEAR A

20. 20
RESULTS
DISTORTION ON THE TOOTH THICKNES FOR
GEAR B
At the temperature 880O
C
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%.

21. 21
RESULTS
DISTORTION ON THE TOOTH THICKNES FOR
GEAR C
Heating temperature
920O
C 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.

22. 22
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%

23. 23
RESULTS
DISTORTION ON ADDENDUM CIRCLE DIAMETER FOR
GEAR B
Distortion 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 820O
C

24. 24
RESULTS
DISTORTION ON THE ADDENDUM CIRCLE DIAMETER FOR
GEAR C
At the temperature
920O
C 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%

25. 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 920O
C, while for this highest value of
distortion will influence to high precision at the tooth contact is not
appropriate.

26. 26
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.