Abstract
This study employs computer simulation to predict residual stresses and distortion in a full-float truck axle subjected to induction scan hardening. Electromagnetic behavior and temporal power distributions within the axle are modeled using Flux2D, with these power distributions subsequently mapped into DANTE software for comprehensive thermal, phase transformation, and stress analysis. The truck axle has three key geometrical regions: the flange/fillet, shaft, and spline. Our study reveals that induction heating and spray quenching processes significantly impact distortion and residual stress distributions. We specifically investigate how spray quenching severity affects these outcomes by simulating varying quenching rates, which can be practically adjusted through spray nozzle design, polymer solution ratio, and quenchant flow rate. Three heat transfer coefficients (5,000, 12,000, and 25,000 W/m²·°C) were applied as thermal boundary conditions during spray quenching while keeping all other parameters constant. Understanding the relationship between heating/quenching parameters and resulting residual stresses and distortion enables optimization of the induction hardening process for enhanced part performance.
