Aufbau einer numerischen Simulationskette für induktionsgehärtete Randschichten

Translated title of the contribution: Development of a numerical simulation chain for induction hardened boundary layers

Roman Aigner

Research output: ThesisMaster's Thesis


The aim of this thesis is to develop a linked simulation chain, which allows a numerical analysis of the induction hardening process. Based on the simulation model parameters, comprehensive studies regarding inductor geometry, required frequencies as well as inductor currents and material properties of the sample are performed. Through this analysis, statements of the resulting metallurgical properties, as wellas of the residual stress and hardness condition in the surface layer of the component, are enabled. This reduces time and cost effort for extensive test sequences significantly. The simulation of the inductive electro-magnetic-thermal heating process is carried out by means of a multiphysical software package. The subsequent thermo-mechanical-metallurgical cooling process including phase changes, distortion, hardness and residual stress distribution is modelled with the aid of the program Sysworld®. Due to the investigated complex sample shape, it is necessary to implement a so-called SDF (Simultaneous Dual Frequency) technology in the electro-magnetic-thermal numerical simulation in which the workpiece is simultaneously charged by a high and a medium-frequency inductor. The subsequent numerical simulation of thermo-mechanical-metallurgical cooling process is optimized in order to perform a parameter study of the cooling conditions by an adaptation of the input card. Furthermore, additional scripts are generated to ensure the data transfer between the two programs, which automate both an evaluation of the temperature distribution as well as the resulting adaptations of the simulation parameters. Finally, the numerically determined, local properties are compared with measured data and thus validates the linked simulation experimentally. The numerically determined boundary layer properties serve as a database for structural durability assessments of induction hardened components. Therefore, this methodology contributes significantly to the efficiency of the design process of case-hardened components.
Translated title of the contributionDevelopment of a numerical simulation chain for induction hardened boundary layers
Original languageGerman
  • Stoschka, Michael, Supervisor (internal)
  • Leitner, Martin, Co-Supervisor (internal)
Award date16 Dec 2016
Publication statusPublished - 2016

Bibliographical note

embargoed until 01-12-2021


  • induction heating
  • induction hardening
  • SDF
  • heat treatment
  • 50CrMo4

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