The standardization of production is a trend in automotive engineering
as uniformly designed; perfectly configured production plans guarantee highly
efficient practices at different sites. The production process is tailored to
different components – a trend which naturally also affects mechanical
engineering, since “off-the-rack” solutions cannot meet this demand. The
example of the induction hardening of steering pinions clearly shows the system
concepts machine manufacturers are developing to react to this Induction Hardening in Faridabad
offers customized systems to integrate hardening into the production flow.
Millions of steering pinions are produced every year by large supply
companies. This component is used in all steering systems and ensures that the
steering force is transferred to the steering gear and then ultimately to the
wheels – a process that happens millions of times over the life cycle of a car.
This means that the strength of these components, and the material used to
produce them, has the very highest priority, making hardening processes
essential. However, hardening components produced in large scale manufacturing
processes often presents a logistical challenge. Many suppliers have the
process completed by a third party in the form of case hardening, requiring a
heat treatment specialist, creating additional costs and planning work.
Hardening in less than one second
Hardening in less than one second
Inductwell.com delivers a whole host of benefits in this
respect. This is a global player with headquarters and develops, manufactures
and sells highly efficient induction heating technology for a very wide range
of industrial applications. The technological alternative to case hardening is
not only faster and more energy efficient, but Induction Hardening can
be integrated perfectly in series production systems where they become integral
components of complete production lines. Making this a viable option is the
speed of the process. While a steering pinion must be heated over a period of
hours for case hardening, the induction process takes less than one second with
the heat applied by the induction of eddy currents.
SDF technology improves component quality
The benefits of a special Inductwell.com innovation are particularly
clear when processing steering pinions – generators featuring simultaneous dual
frequency (SDF) which supply the energy for the hardening machines. With SDF,
two different frequencies are applied to the work piece. While mid-frequencies
generally penetrate more deeply and, above all, heat the foot of the tooth,
high frequencies heat the head of the tooth. The heating process on the
steering pinion using SDF therefore achieves absolutely uniform depth and
temperature levels. This ensures a standard hardening finish even on large
modules. “We tailor the required energy source perfectly to the component.
There are no standard solutions.
Hardening technology from a single source
The same also applies to the eldec module induction (MIND) series of
hardening machines, also perfectly tailored to the work piece dimensions,
required hardening finish and batch size. Only time-tested components are used
thanks to the company’s modular element system. This benefits the stability of
the systems and also means that the technology offers proven value for the
investment. Finally, made with micrometer precision based on the work piece
using 3-D CAD software, the production of the inductor tools also meets the
customer’s specifications. “We supply our customers with a tailored machine
which includes robot automation systems, if necessary. They can be integrated
perfectly in production lines with soft and subsequent hard machining processes
as a complete hardening system,” explains Rechtacek. Steering pinion
production from the raw part to the finished component can then be carried out
in a multi-stage process which may also feature grinding and turning machines
from EMAG. Automotive customers are supplied with a complete turnkey solution.
Focusing on machining quality
