This paper revisits a case study presented at Heat Treat 2009, investigating the failure of induction coils used for heat treating automotive wheel hubs. At the time, computer simulation was beginning to allow for virtual prototyping of heat treat applications as an alternative to experimental testing. As explained in the original paper on p. 86 of the 2009 HTS conference proceedings, although simulation helped in the development of a more robust coil, it was not used to pinpoint the cause of failure. In this current work, the authors tackle the same problem aided by more than a decade of improvements in compute power and finite element analysis techniques. To highlight the leaps made in virtual prototyping, the induction hardening coil previously analyzed using an axisymmetric 2D model is now examined using more precise 3D electromagnetic and thermal models while accounting for the rotation of the part.

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