Abstract
Dual frequency induction hardening can be a low distortion alternative to case hardening for gearings. However, profound process understanding is still lacking, which is reflected by the absence of appropriate models allowing the prediction of final component properties in terms of residual stresses and distortion. In order to close this gap, a 2-D numerical model has been developed, considering short time austenitization kinetics of quenched and tempered AISI 4140. The induction heating model considering the nonlinear magnetic material behaviour is realized with MSC.Marc®, whereas the mechanical response is implemented in Abaqus/Standard®. The comparison of residual stresses and distortion with experimental results shows that the developed model is in good agreement. Numerical investigations have shown that the core temperature and the TRIP strain during the martensitic transformation will determine the quantitative distribution of the residual stresses.