Optimization of induction heating process for ball screw based on finite element analysis

doi:10.13251/j.issn.0254-6051.2025.01.037

Abstract

Abstract: In order to optimize the induction heating process of ball screw and improve the uniformity of its surface temperature distribution, thereby improving its manufacturing precision and performance, a finite element model was constructed by means of electromagnetic simulation software to analyze the influence of different process parameters on the surface temperature distribution of the ball screw during both static and dynamic induction heating. The results show that an excessively small internal diameter of the induction coil results in a narrow gap between the workpiece and the coil, which can easily lead to overheating of the workpiece surface. Conversely, an excessively large internal diameter results in a wide gap, reducing heating efficiency and resulting in a shallow heating layer. Therefore, selecting an induction coil with an appropriate internal diameter is essential for ensuring the quality of heating. The double-turn coil demonstrates superior performance in terms of heating efficiency and temperature uniformity. Employing high voltage and an appropriate current frequency can improve heating efficiency and control the depth of heating layer. For dynamic heating, a scanning speed of 6-10 mm/s is recommended to achieve a balance between heating efficiency and process stability.

Key words: ball screw, GCr15 steel, induction heating, finite element analysis

CLC Number:

TG156.33

Li Mingzhe, Chen Baofeng, Zhang Wenliang, Sun Lizhuang, Zhang Lun, Liu Junjie. Optimization of induction heating process for ball screw based on finite element analysis[J]. Heat Treatment of Metals, 2025, 50(1): 236-242.

References

[1]黄韶娟, 盛伯浩, 吴进军, 等. 我国高档数控机床产业发展支撑体系初探[J]. 制造技术与机床, 2019(1): 44-48.
Huang Shaojuan, Sheng Bohao, Wu Jinjun, et al. The primary exploration of the industrial development strong point of China's high-grade CNC machine tool industry[J]. Manufacturing Technology and Machine Tool, 2019(1): 44-48.
[2]吴元徽. 滚珠丝杠表面感应淬火的质量控制[J]. 金属热处理, 2011, 36(1): 120-121.
Wu Yuanhui. Quality control of surface inductive quenching for ball screw[J]. Heat Treatment of Metals, 2011, 36(1): 120-121.
[3]冷洁. 我国机床行业发展现状与问题思考[J]. 锻压装备与制造技术, 2023, 58(3): 136-138.
Leng Jie. China's machine tool industry development status and problems thinking[J]. China Metal Forming Equipment and Manufacturing Technology, 2023, 58(3): 136-138.
[4]Ding Xia, Gai Yuhong, Li Baomin, et al. Study on the induction quenching process and fatigue testing for Cr-Mo steel ball screw[J]. Advanced Materials Research, 2018, 1145: 154-159.
[5]孙颖, 贺连芳, 李志超, 等. 滚珠丝杠仿形感应淬火工艺设计及数值模拟[J]. 材料热处理学报, 2022, 43(2): 161-169.
Sun Ying, He Lianfang, Li Zhichao, et al. Process design and numerical simulation of profiling induction hardening of ball screw[J]. Transactions of Materials and Heat Treatment, 2022, 43(2): 161-169.
[6]Kranjc M, Zupanic A, Miklavcic D, et al. Numerical analysis and thermographic investigation of induction heating[J]. International Journal of Heat and Mass Transfer, 2010, 53(17/18): 3585-3591.
[7]Liu Hao, Rao Jianhua. Temperature field simulation of steel pipe in the induction quenching and tempering process[J]. Journal of Computational and Theoretical Nanoscience, 2012, 9(9): 1200-1204.
[8]张洪云. 精化55钢滚珠丝杠双匝感应加热淬火及性能分析[J]. 热加工工艺, 2017, 46(24): 205-210.
Zhang Hongyun. Induction hardening and property analysis of refined 55 steel ball screw with double turn[J]. Hot Working Technology, 2017, 46(24): 205-210.
[9]盖康, 贺连芳, 张春芝, 等. 基于RSM的丝杠感应淬火工艺数值模拟及参数优化[J]. 材料热处理学报, 2016, 37(S1): 146-152.
Gai Kang, He Lianfang, Zhang Chunzhi, et al. Numerical simulation of process and parameter optimization in the induction hardening of screw based on the RAM[J]. Transactions of Materials and Heat Treatment, 2016, 37(S1): 146-152.
[10]Li Huiping, He Lianfang, Gai Kang, et al. Numerical simulation and experimental investigation on the induction hardening of a ball screw[J]. Materials and Design, 2015, 87(15): 863-876.
[11]沈庆通, 黄志. 感应热处理技术300问[M]. 北京: 机械工业出版社, 2013: 18-19.
Shen Qingtong, Huang Zhi. Induction Heat Treatment Technology 300 Problems[M]. Beijing: China Machine Press, 2013: 18-19.

[1]	Li Xianjun, Jiang Chao, Zhang Minghao, Zhang Wenliang, Sun Lizhuang. Development of induction heat treatment technology and equipment for key components of machine tool [J]. Heat Treatment of Metals, 2025, 50(1): 308-316.
[2]	Liang Fengrui, Su Hang, Chai Feng, Sun Mingxuan. Difference of microstructure and properties between bulb and flat of Cu-bearing low-carbon bulb flat steel [J]. Heat Treatment of Metals, 2024, 49(9): 11-17.
[3]	Gao Xinbo, Qin Qingliang. Application of model-free adaptive control in heat treatment of large 12Cr2Mo1V steel [J]. Heat Treatment of Metals, 2024, 49(9): 290-296.
[4]	Dong Jiaxin, Luo Yun, Jiang Wenchun, Gu Wenbin, Dong Pijian. Control and parameter optimization in electromagnetic induction heating temperature uniformity of large thick-walled cylinder [J]. Heat Treatment of Metals, 2024, 49(3): 275-278.
[5]	Liang Jianquan, Xiao Yao, Wei Yulin, Zhao Daifu, Han Yi. Asynchronous dual-frequency induction heating of gears based on irregular coil [J]. Heat Treatment of Metals, 2024, 49(12): 274-283.
[6]	Liu Gang, Peng Peng, Wang Xinyu, Zhang Zengguang, Cui Jing, Liao Qiyu. Verification module of stabilizing treatment fixture based on finite element analysis for titanium alloy [J]. Heat Treatment of Metals, 2024, 49(12): 284-288.
[7]	Wang Weimin, Liu Anqi, Guo Chuncheng, Da Zhongzhong, Qi Haiquan, Han Xiangnan, Xue Qihe, Wei Minjun. Effect of composite heating process of induction furnace and pit furnace on quenched and tempered microstructure and mechanical properties of 40Cr steel [J]. Heat Treatment of Metals, 2023, 48(11): 185-190.
[8]	Chen Zhuohao, Xie Hui. Numerical analysis of continuous moving induction heating with dual-loop coil [J]. Heat Treatment of Metals, 2022, 47(8): 105-111.
[9]	Jiao Qingyang, Zhao Dong, Wang Xinyu, Li Shijian. Thermo-physical properties of tempered AerMet100 steel [J]. Heat Treatment of Metals, 2022, 47(6): 168-172.
[10]	Zhao Xin, Chen Zhengzong, Zhao Haiping. Simulation of heating process for martensitic heat resistant steel G115 heavy pipe blanks [J]. Heat Treatment of Metals, 2022, 47(4): 208-212.
[11]	Li Zhu, Zhang Qingyong, Kong Linghua, Lian Guofu, Yang Jinwei. Characterization of hardness for GCr15 steel based on laser-induced breakdown spectroscopy [J]. Heat Treatment of Metals, 2022, 47(1): 284-289.
[12]	Yan Chaohui, Wang Youhua, Liu Chengcheng, Wu Shipu. Influence of transverse flux induction heating excitation parameters on steel strip temperature and heater optimization [J]. Heat Treatment of Metals, 2021, 46(5): 87-94.
[13]	Zhou Denghu, Hou Qingyu, Han Weixue, Jiang Yan, Huang Zhenyi. Austenitization kinetic characteristics and microstructure evolution of as-cast GCr15 steel during continuous heating [J]. Heat Treatment of Metals, 2021, 46(11): 17-23.
[14]	Guo Huimin, Li Bo, Zhang Liqun, Tao Jinglei, Huang Wei, Pei Xiuyuan, Xiao Junfeng, Nan Qing. Effect of real TGO interface topography on interface stress of thermal barrier coatings [J]. Heat Treatment of Metals, 2021, 46(11): 232-235.
[15]	Lin Lei, He Feifei, Lin Gang, Chen Yong, Ran Haijun. Optimal design of quenching fixture for multi-arc head used in aerospace [J]. Heat Treatment of Metals, 2020, 45(9): 257-261.