Spiral-scanning electromagnetic heating of helical gears based on a coordinate system linkage method

• Published in: Applied thermal engineering 2024-10, Vol.255, p.123999, Article 123999
• Main Authors: Han, Yi, Shao, Zhuge, Liu, Yuejun, Wang, Dashuang, Xiao, Yao, Zhang, Tianxiong
• Format: Article
• Language: English
• Subjects: Dynamic heating; Electromagnetic heating; Helical gears; Temperature uniformity
• ISSN: 1359-4311
• DOI: 10.1016/j.applthermaleng.2024.123999

•Propose a coordinate system linkage method of spiral electromagnetic heating.•The “gradual speed change” method was designed to reduce temperature gradients.•Altering the initial heating position of the coil can balance the end-face effect. In the field of electromagnetic heating, continuous scanning heating is one of the crucial approaches to minimizing the temperature distribution gradient in basic components such as helical gears. However, in the process of dynamic heating, the spiral tooth shape of helical gears complicates the coupling relationship between the induction coil and the gear. Therefore, the distribution mechanism of magneto-thermal properties is difficult to investigate. A new spiral scanning electromagnetic heating method for helical gears − Coordinate System Linkage Method (CSLM) −is proposed. To facilitate the precise movement of the profiling induction coil, we formulate a set of coordinate systems by integrating the spiral characteristics of the gear. The mathematical model is constructed by segmenting the spiral-scanning motion and delineating its interrelationships. On this basis, an electric–magnetic-thermal coupling model specific to spiral-scanning heating is enabled. For the process of spiral-scanning heating, two coil scanning methods are designed: “sudden speed change” and “gradual speed change”. A comparative study reveals the temperature difference along the tooth width with the “gradual speed change” method is smaller than that with the “sudden speed change” method. Moreover, controlling the coil scanning speed appropriately can minimize the temperature gradient of the entire gear, while changing the initial heating position of the coil can balance the end-face effect. Both of these measures effectively equalize the temperature distribution along the tooth width. Finally, an experimental platform for spiral scanning heating of the helical gear is constructed to confirm the correctness of the simulation results, which likewise demonstrates the effectiveness of the method in improving temperature uniformity. This study provides a measurable theoretical reference basis for the electromagnetic heat transfer of irregular workpieces with spiral features to accurately control the temperature gradient.