Multi-Scale Optimisation of induction hardening processes for complex geometrical parts – OPTIPRO-INDUX

The goal of this project is to implement a process of analysis, control and optimisation of a surface induction heat treatment process followed by a quenching stage. The part which will be used in this project if an automotive crankshaft, which is one of the most critical parts in the future powertrains prescribed by the EURO6 regulations.
This part may be reinforced in the most mechanically loaded areas by burnishing or by induction. If induction has become largely used for large-size engines, its use for automobiles is scarcer, mostly due to badly mastered process and costs. Indeed, small crankshafts are more sensitive to deformation after induction hardening due to their geometry (weaker massiveness). These distortions make the use of induction hardening quite delicate and increase the global cost of the part.
The analysis, study approach and results of this project will not be limited to crankshaft production, but may alos be reused for studying the induction hardening of other parts with a complex geometry subject to distortions
The scientific approach will be based on the use of complementary approaches to reach the prescribed goals:
- accurate understanding of material behaviour during fast heating
- modelling of multiphyssics couplings between electromagnetism, heat transfer, solid mechanics and metallurgical phases transformation
- experimental validation of the optimised solutions
The complementarity between consortium partners (laboratories in the field of numerical modelling of processes and in material science, automotive industry, steel industry, experts in electromagnetic processing of materials) will help to make this project to a success.
Project benefits are manifold
- Scientific: improve knowledge of metallurgical behaviour for fats heating, fine analysis of thermal-mechanical-metallurgical couplings, progress towards process optimisation through an accurate predictive multphysics computational model
- Process and material optimisation (structure, hardness, residual stresses, deformation,..) with the help of computational modelling (predictive aspects) to better take it into account in the part design process
- Technological: induction heat treatment is an economic process easily implementable on a new production line, and which can potentially lead to very good in-use properties
- Economical: enable manufacturing of small automotive crankshafts with minimal and reproducible deformation. We need to recall here that straightening of induction heat treated crankshafts cannot be carried out – since it leads either to unfavourable residual stresses, or worse to breaking
- Environmental; reduction of energy consumption during manufacturing processes complies with sustainable development goals.