The Design of a System for the Induction Hardening of Steels Using Simulation Parameters

This paper presents the development of a piece of induction hardening equipment based on the foundations of the design, starting from zero. It was intended for steels in general, and was tested on unalloyed low- and medium-carbon steels, whereas the results for EN 1C60 steel are shown in this study. The EN 1C60 steel showed average results, and was chosen as a representative of a wider group of engineering steels. The main objective of this work was to develop a flexible system for mild steel hardening that can be used for various hardening depths and steel types. The system design’s priorities were the use of standard electronic components to avoid supply chain disruptions and to achieve high energy efficiency. The construction of the prototype in full detail is also presented. The optimal process parameters are listed, as well as the procedure of their obtaining by using the appropriate simulation method. The key parameters were adjusted in consecutive steps. This study resulted in high matching between the model predictions and experimental results. The basic goal of this research was achieved, with the system having a minimum energy efficiency of 75.3%, a most frequent energy efficiency of 90% and a maximum energy efficiency of 95.1%.