The possibility to manage stress and strain in hardened parts might be beneficial for a number of induction hardening applications. The most important of these benefits is the improvement of fatigue strength, avoidance of cracks and minimization of distortion. An appropriate and powerful way to take the stress and strain into account during the development of a process is to make use of computer simulations. Own developed and commercial software packages have been coupled to incorporate the electromagnetic task into the calculations. The simulations have been performed with a following analysis of the results. The influences of two different values of quenching intensity, strength of initial material structure, strength of austenite, surface power density-frequency-time-combination, and work piece diameter on the residual stress are studied.

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