Induction

The induction hardening treatments in medium and high frequency are carried out in state-of-the-art plants interconnected in 4.0 mode, which guarantee the monitoring and recording of process parameters. Thanks to the know-how gained over the years, the Temprasud Group has a fleet of inductors and showers (over 500) made in-house and adaptable according to the specific geometries of the component.

Induction surface hardening has the main purpose of improving the wear and fatigue resistance of hardened parts. This treatment is preferred in the event of pieces that are too large, difficult to treat on a massive scale, or if there are technological needs to harden only some surfaces, the need to limit deformations and if there is a desire to obtain diversified hardening depths.

Capabilities

Below is the detail of the plants present in the two establishments.

Temprasud (Fresagrandinaria)

2 plants for high-frequency induction hardening of small parts (gears, shafts) with the following characteristics:

  • CNC control of the Z axis and manual adjustment of the X-Y axes, with a load capacity of 50 kg;
  • operating power from 50 to 100 kW and the possibility of choosing a working frequency between 100 and 300 kHz;
  • two-position rotary table for series production;
  • process control with recording of the critical parameters and NC piece alarm.

2 plants for medium-frequency induction hardening of medium- and large-sized parts and complex geometry with the following characteristics:

  • CNC control of the 4 axes, with a load capacity of up to 1,500 kg;
  • 2 horizontal benches with maximum strokes 600 x 4500 x H 1,100 mm;
  • operating power from 70 to 200 kW and the possibility of choosing a working frequency between 4 and 100 kHz;
  • 4-position rotary table for series production;
  • process control with recording of the critical parameters and NC piece alarm.

 

Unitrat (Bari)

1 plant for high-frequency induction hardening of small parts (shafts, hubs, pins, bushings) with the following characteristics:

  • CNC control of the Z axis and of the rotation; manual adjustment of the X-Y axes, with a load capacity of 100 kg;
  • operating power from 100 kW and self-adapting working frequency from 30 to 300 kHz depending on the load;
  • 4-position multiplier for series production;

1 plant for medium-frequency induction hardening of medium-sized parts with the following characteristics:

  • CNC control of the Z axis, with a load capacity at a single station of 70 kg
  • 1 4-position rotary table for series production with a maximum capacity of 70 kg
  • 150 kW operating power and choice of 2 self-adapting frequencies (high and medium) of 10-30 kHz
  • 1 tailstock for treatment of shafts with a maximum length of 400 mm

2 plants for medium- and low-frequency induction hardening of medium- and large-sized parts and complex geometry with the following characteristics:

  • 1 Generator with 300 kW power and variable frequency from 4 kHz to 10 kHz
  • 1 Workbench with XY controlled axes; maximum stroke 2,480 mm, also equipped with rotation control for maximum overall dimensions ø 1,200x 2,400 mm and maximum capacity of 2,000 kg.
  • 1 vertical workbench with motorized tailstock for treating shafts with maximum dimensions ø 400 x 3,500 mm and maximum capacity of 2,000 kg

Treatments

Induction hardening consists of a first phase of austenitization heating, located only in the area to be hardened, followed by martensitic hardening, through the use of polymers and finally by stress relieving through induction or in massive furnaces. The heating of the component takes place by Joule effect thanks to the induced currents generated in the piece by an external electromagnetic field.

The depth of the induced current and the thickness of the material affected by the heating is inversely proportional to the square root of the frequency set by the generator.

High frequencies (between 100 and 300 kHz) are used to obtain precise and limited hardening profiles (up to about 5 mm) normally on small and medium-sized components and limited thicknesses.

Medium frequencies (between 4 and 100 kHz) are used to obtain elevated hardening profiles (over 5 mm) on large components and greater thicknesses.

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