Sprocket Gear Induction Hardening Machine

A sprocket gear induction hardening machine is a processing equipment for surface induction hardening or full gear, sprocket, and other shafts workpiece induction quenching process, the purpose of the gear hardening is to strengthen its toughness.

Induction hardening is a method of heating metal parts by electromagnetic induction and then quenching them to create a hardened layer on the surface or the whole part. Induction hardening can improve the wear resistance, contact fatigue strength, endurance, and impact strength of gears and sprockets.

Depending on the size of the gear, the required hardness pattern, and tooth geometry, gears are induction hardened by encircling the whole gear (external or internal) with an induction coil (the so-called “spin hardening”) or, for larger gears, hardening them tooth-by-tooth with either gap-by-gap or tip-by-tip heat-treating techniques.

What parts are included in the sprocket hardening plant?

The parts included in the sprocket hardening plant may vary depending on the method of induction hardening used, but generally, they consist of:

l?An induction coil that generates an alternating magnetic field to heat the sprocket teeth by eddy currents.

l?A power supply that delivers current to the induction coil and controls the frequency, power, and duration of heating.

l?A quenching system that sprays water or oil on the heated sprocket teeth to rapidly cool them and create a hardened layer.

l?A machine tool that holds and rotates the sprocket during the hardening process and allows for precise positioning and movement of the induction coil.

l?A control system that monitors and regulates the hardening parameters such as temperature, hardness, case depth, and uniformity.

How long does it take to harden a sprocket gear?

The time it takes to harden a sprocket gear depends on several factors, such as the size and shape of the sprocket, the method and frequency of induction heating, the quenching medium and rate, and the desired hardness and case depth. According to some sources, the typical heating time for induction hardening of gears ranges from “a few seconds to a few minutes”. For example, a spur gear with a pitch of 4 mm and a tooth thickness of 245 mils can be heated to the austenitizing temperature in about “10 seconds” at a frequency of 27 kHz. The quenching time may vary depending on the type and flow rate of the quenching medium (water or oil), but it is usually “less than the heating time”. Therefore, the total hardening time for a sprocket gear may be estimated as “a few tens of seconds”. However, this is only a rough approximation and the actual hardening time may differ depending on the specific conditions and requirements of each application.

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How to do sprocket gear hardening with induction heating?

?Sprocket gear hardening with induction heating is a process that involves the following steps:

- Select a suitable “induction coil” that can encircle the whole sprocket or each tooth individually and generate an alternating magnetic field to heat the sprocket teeth by eddy currents.

- Choosing an appropriate “power supply” that can deliver current to the induction coil and control the frequency, power, and duration of heating. The frequency affects the depth of heating and the uniformity of temperature distribution. The power and duration affect the final temperature and the case depth of hardening.

- Applying a “quenching system” that can spray water or oil on the heated sprocket teeth to rapidly cool them and create a hardened layer. The quenching medium and rate affect the hardness, residual stress, and distortion of the sprocket.

- Using a “machine tool” that can hold and rotate the sprocket during the hardening process and allow for precise positioning and movement of the induction coil. The rotation speed and direction affect the heating uniformity and efficiency.

- Employing a “control system” that can monitor and regulate the hardening parameters such as temperature, hardness, case depth, and uniformity. The control system can also provide feedback and adjustment to optimize the hardening process.

Zhengzhou Ketchan Electronic Co., Ltd. is one of the leading sprocket gear induction hardening system manufacturers in China, we supplied different gears induction hardening systems since 2000, pleased to share more with you, Contact us for now.

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