Case Studies
Analysis
Heat Treatment Process Development for Gears Using Computer Modeling
For this process, the LPS model was executed for 4120 steel, with a goal of at least 60 HRC surface hardness, and with an effective case depth of 1.5mm.
The recipe generated from the carburization tool was then used in a finite element model for analysis of the part.
February 20, 2024
Cracking
Bearing Ring Cracking in Press Quenching
The basis of this study is a 4” OD bearing ring, made of AISI 52100 steel. A large number of these bearing rings were failing during the press quenching process, as seen in the table. Large circumferential cracks could be seen in the bearing race in over half of the parts after quench and temper.
August 24, 2016
Distortion
Correcting Bevel Gear Distortion from Heat Treat
Nonuniform and excessive distortion of the tooth in the axial direction during oil quenching.
Machining to correct distortion removes residual compressive stresses, damaging the fatigue performance.
Problem not discovered until after production began. Cost to correct at this stage is very high.
June 15, 2016
Stress
Improving Gear Tooth Bending Fatigue Life
Helicopter transmission life limits load carrying capacity and acceleration. Improved gear bending fatigue life will allow heavier loads and improved acceleration. New designs are costly and require long development times. A process improvement for an existing design saves time and money.
June 15, 2016
Induction
Induction Hardening of Welded Tube Shaft
In-process tensile stress in an induction hardened 4130/10B37 welded tube shaft was investigated. Thermal and transformation stresses during heat treatment were examined to determine source of bond line cracking and potential remedies.
June 15, 2016
Induction
Oil Hole Crack of Crankshaft During Induction Hardening
Cracking at oil holes on pin and main bearing sections of crankshafts during induction hardening occurs due to thermal stress during spray quenching. The problem arises due to the angle of the hole and the nonuniform mass distribution.
June 15, 2016
resources
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