History of RF Division

Denki Kogyo Co., Ltd. (hereinafter referred to as DKK) has
started RF induction heating business in 1952 at Haneda, Tokyo
and developed vacuum tube type oscillator capable of 150kW
output that was the first one in Japan.
DKK has started its business with consigned processing (job-
shop business) of RF induction heat treatment (hardening/
tempering). DKK had intended to accumulate relevant technology
and experience 3 to 4 years to improve the heat-treating
equipments before starting sales of them in 1955.
In 1965∼1975, DKK had increased sales amount of both
processing and machines for heat-treating backed by high growth
of Japanese economy and industries associated with automobile
production. DKK has built new plant specialized for the both
businesses above in 1968 at Atsugi, Kanagawa prefecture and in
1981 expanded the plant for machine production and R ＆ D of
heat treatment which has become the largest one in our industry.
DKK has developed generators starting with vacuum tube type
oscillators, after that electromotor generators, thyristor inverters,
and transistor inverter generators one after another. The first
300kW transistor inverter in the world was developed and
delivered by DKK.
Regarding hardening machine, DKK has developed and
produced from manual to full automatic machine, and has applied
numerical control (NC) on hardening machine for the first time in
the world. DKK has introduced the technology of rotation type full
automatic crankshaft hardening machine from Alfing Kessler
GmbH, Germany based upon the cooperation agreement, and has
been producing the machine domestically.
At the present, DKK adopts CAD in all the fields of designing
RF induction heat treating equipments, which are exported to
more than 20 countries, and has been becoming No.1 Company in
our industry in its supplies, sales amounts and productivity.
Further, DKK has acquired the certificate of ISO 9001 for the
first time in the RF induction heat-treating equipment industry on
February 1997, and is proud of its technology and quality, which
are acknowledged in the world.

Outline of RF Administration ATSUGI PLANT

Site: 36,000m2 Panoramic view of Atsugi Plant
Floor space: 18,000m2
Items of products
1. RF induction heating equipment
・Hardening and tempering equipment
・Iron and steel (slab) heating equipment
・Brazing equipment
・Forge heating equipment
・Melting furnace
・Pipe welding equipment
・General heating equipment
2. RF applied products
・RF power generator for plasma heating use and
accelerator use
・Microwave plasma CVD equipment
・RF power generator for lighting use Inside Atsugi Plant
3. Compact RF accelerator for electron beam irradiation
4. RF induction heat treatment trial processing
5. Vacuum furnace for metal heat treatment

Outline of RF Administration group companies

Denko Techno Heat Co., Ltd.
Sales items
1. Consigned processing (job-shop) of RF induction heat
treatment
2. RF induction heat treatment trial processing
3. Manufacturing of induction heating inductor
Location
Hamamatsu, Kariya, Suzuka, Shiga
Koshuha Kogyo Co., Ltd.
Sales items Inside a design building
Sheet metal processing, Manufacturing of chassis
Location
in the site of ATSUGI PLANT
Denko Metallurgical Technology Co., Ltd.
Sales items
1. Vacuum furnace for metal heat treatment and
associated equipment
2. Compaction press for hard metal powder
3. Precision grinding machine
Location
in the head office of DKK Co., Ltd.

1
Principle of Induction Heating
The principle of induction heating by RF electric current is Fig.-1: Principle of induction heating
shown in Fig.-1, there an electric conductor such as iron or steel
placed in the inductor is heated rapidly by induced eddy current AC magnetic flux
caused by electromagnetic induction, and hysteretic heat loss,
RF
which is generated by vibration and friction of each molecule in
electric current
magnetic material under AC magnetic flux.
As RF frequency, which is higher than that of commercial
electric power, is used for induction heating, induced current
flows only in the limited area near surface of heated material
because of skin effect and proximity effect, and heat loss occurs RF
only there by eddy current and hysteretic loss. The skin effect is voltage
the phenomenon, which RF electric current flows only in the
limited area near surface of conductive material, and proximity
effect is the phenomenon, which the primary current in the
inductor and the secondary current in the conductive material pull
each other because the direction of current is opposite each other,
and flows in the limited area near surface where distance is
nearest each other. Heating inductor
Fig.-2 shows the relation between frequency and depth of RF （a） Heating material

electric current flow for steel material heated by induction at 1,000

degree. The depth depends upon the frequency and as the
frequency is higher, the depth becomes smaller as shown in the
curves in Fig.-2.
The penetration depth is defined as the point where RF electric
current decreases to about 37％ (1/e =1/2.718=0.368; e is the base
of natural logarithm) compared with the current at the surface and
normally expressed asδ. In Fig.-2, the penetration depth is shown
as the points, which are the cross points of line A with the current
penetration curves. The penetration depthδ is calculated as
RF
follows. Load or heating electric current
material
ρ Eddy current
δ=5.03× μf (cm) Heating inductor
δ= penetration depth (cm)
μ= specific permeability （b）
(magnetic material: μ＞1, non-magnetic material: μ= 1 )
f = frequency (Hz)
ρ= specific resistance (μΩ・cm)
This formula shows that as the frequency is higher, δwill be Fig.-2: Electric current distribution and penetration depthδ (cm) for steel
smaller and the heating will be concentrated at the surface in case material (at 1,000 degree)

the materials are same. However in actual heating, the heated

depth tends to become bigger because of heat conduction in the 1.0
heated material. (Refer to Setting of Hardening Condition item
(3) Choice of frequency) 0.9

0.8

0.7 δ1δ2δ3δ4 shows the depth of

50Hz penetration in each frequency
0.6 1000Hz

0.5 3000Hz

0.4 A
0.368
0.3 10,000Hz
Distribution of electric
current's density
0.2

0.1

δ1 2 3 4 5 6 7 8 9 10 11 12 13
Surface δ2 Depth （cm）
δ3
δ4

2
 Aims and Features of RF Heat Processing (Hardening and Tempering)
The aims of RF heat processing (hardening and tempering) are
that to make harden the surface of mechanical structural parts so as
to improve the wearability and to increase the mechanical property
especially fatigue durability.
RF heat processing is a method to make a hardening layer on the
surface of a steel material by heating the surface rapidly up to
hardening temperature (generally up to 900℃) and after that
cooling rapidly using cooling water. This method has many
features.
(1) Heating efficiency is better because of direct heating.
(2) Oxidization is less because of short time heating.
(3) Partial heating is possible and the choice of
hardening depth is optional.
(4) Distortion is smaller compared to that of other
methods.
(5) Improve wear ability and fatigue durability.
(6) Generally, even cheaper carbon steel substitutes for
special steel.
(7) Easy to adjust hardening condition.
(8) Easy for automating.
(9) Possible for inserting into machine processing line.
(10) Harmless in working environment (No pollution).

Methods of RF Hardening
There are two methods in RF hardening.
(1) Stationary hardening (one-shot hardening) method=
heating and quenching (cooling) are done at the same
position
①Revolving method of hardening material (work-piece)
Revolve the hardening material in order to heat and cool
evenly.
(Always done in case the hardening material is revolvable.)
Ex) gear, sprocket, crankshaft, camshaft, axle-shaft, drive
shaft, CVJ etc.
②Stationary method of hardening material
This method is adopted in case hardening material is not
revolvable.
Ex) rocker arm, rack-steering, shift-rail etc.
③Cooling system
There are two methods in cooling system.
1) Cooling is done at the same position as that of heating. Just
after heating, cooling water is jetted from small holes of
inductor (commonly used as cooling jacket) toward the
heated portion of work-piece at the same position as
heating.
2) Cooling position differs from heating position. Just after
heating, the work-piece is shifted into the cooling jacket,
and then cooling water is jetted from small holes of cooling
jacket toward heated portion of work-piece. Or, just after
heating, the work-piece is shifted and soaked into the
cooling pan, which is filled with cooling water.
(Fig.3 shows the example of stationary one-shot hardening
method that differs in cooling system.)
Fig.-3: Stationary hardening system, which differs in cooling method
Heating material
Hardening layer
(2) Scanning hardening method = heating is done partly and
the heated portion is hardened, and heating inductor travels
through longish direction of work-piece successively
①Scanning hardening method with revolving work-piece.
Used for work-pieces, which are revolvable, such as axle
parts.
Ex) pin, bush, axle-shaft, drive shaft, ballpoint screw, piston
rod etc.
②Scanning hardening method without revolving work-piece.
Used for work-pieces, which are not revolvable, such as plane
surface of work-piece or complicated formed inside of work-
piece.
Ex) lathe bed, direct move guide-rail, link, groove of tri-pot
housing etc.
③There are two methods in scanning hardening generally.
1) The heating inductor remains stationary and heating
material travels. This method is adopted in case the size
and weight of heating material is small and so on.
2) The heating material remains stationary and heating
inductor travels. This method is adopted in case the size
and weight of heating material is big and so on.
④Cooling system
There are two methods in cooling system.
1) Cooling water is jetted successively from small holes of
inductor (commonly used as cooling jacket) toward the
heated portion of work-piece.
2) Cooling water is jetted from cooling jacket adjacent to
inductor toward the heated portion of work-piece.
(Fig.-4 shows the example of scanning hardening method
that differs in cooling system.)
Fig.-4: Scanning hardening system, which differs in cooling method
Heating material

yyy
,,, yy
,,
Heating inductor

,,,
yyy y
,
yyyy,
,,,
Cooling ,yyy
y,
yy
,,, Cooling water ,,
,,
Cooling
,,
Heating layer

,,,
yyy ,,
yy
,,
Heating inductor

,, ,,
water Cooling water
water

(a) Heating inductor jet cooling method ,, ,, Heating material

,,
yy ,,y
,,y
Heating material Hardening layer

,,
yy
, ,,y,,y
Heating layer Heating inductor Heating Heating inductor

,,
layer

yy
,,
, yy
,,
yyy
,,,,,
yy
,,
(a) Heating inductor

,,
  jet cooling method
,,,,y
yy
Cooling link
(cooling jacket)

yyy
,,,
yy
,, ,y
yy
,,
Cooling link

yy
,, y
,, ,,,,,y,,
yy
Hardening layer (cooling jacket) Cooling water Cooling
water

yy,y,
,, ,y
yy
Cooling Hardening layer
Cooling water
water

(b)Cooling jacket jet cooling method (b) Cooling jacket jet cooling method

3
Setting of Hardening Condition
(1) Choice of frequency and electric power density Fig.-5: Relation between hardening depth of steel, frequency, power density and heating time
For effective RF hardening, the suitable frequency of RF power
Power curve Time curve
generator must be chosen. The quality of hardening layer obtained
1000 100
by RF hardening depends upon frequency, electric power density,

1KH
heating temperature, cooling speed, pre-processed condition (e.g.

z
10
cold or warm or hot temperature forging), and so on. Therefore,

Surface electric power density（kW/cm2）

KH
z
40
frequency and power density must be chosen according to the size

0K
100 10

Hz
of work-piece and hardening specifications.
The capacity of RF power generator is to be decided according to

Heating time (s)

the mass, heating temperature and heating time of heating material.
The calculation of heating power except heat losses in inductor and 10 1

z
of coupling between inductor and work-piece is given as follows.

KH
Hz
400
10K

1KHz
P (Required power) = P1 + P2 + P3 + P4 1 0.1
P1 = Absorbed power by heating material (Net absorbedpower)
P2 = Radiation heat loss
P3 = Convection heat loss 0.1
P4 = Conduction heat loss 0.1 1 10 100
Hardening layer depth（mm）
P1, P2, P3 and P4 are calculated as follows.
P1 = 4.186×M×C×ΔT（kW/sec）
Table 1: Relation of practical frequency to the size of hardening material and hardening layer depth
M = Mass kg
Hardening layer depth Diameter of round bar Practical frequency
C = Specific heat
(mm) (mm) (kHz)
ΔT = Surface temperature rise ℃
0.5~1.0 6~25 400・200
P2 = 5.74 e× 273＋t 2 − 273＋t 1
4 4

〔（ 1000）（ 1000）〕 W/cm2

t 1 = Normal temperature 1.2~2.5 11~16 400・200・30
t 2 = Heating temperature 16~25 400・200・30(10)
e = Radiation rate (steel:0.8)
P3 = 159ΔT（μW/cm2） 25~50 200・30・10
ΔT = Surface temperature rise ℃ Over 50 30・10
μW = Micro watt
KCS 2.5~5.0 19~25 30・10
P4 = 3.72ΔT t （W/cm ）
2

K = Heat conductivity 25~100 3・10・(30)

C = Average specific heat
Over 100 3・10
S = Density (g/cm3)
t = Heating time ※ Frequency ( ) means available frequency
Table 2: Relation of total hardening layer depth to frequency and power density
Required electric power P is supplied from RF generator through Electric power density
(2)※ （kW/cm2）(1)※
inductor. The electric power P is calculated as shown above. The
heating mass is the product of surface hardening area, hardening Frequency (kHz) Toal hardening layer Low Middle High
depth (mm) (3)※ (4)※ (5)※
layer depth and specific gravity. However, accurate calculation of
400 0.3~1.2 1 1.5 2
heat losses such as heat conduction loss and so on is difficult. So,
practically it is better to calculate based on the experienced data. 400 1.2~2.3 0.5 0.8 1.2
Fig.-5 shows the relation between hardening depth of steel,
10 1.5~2.3 1.2 1.5 2.5
frequency, power density and heating time.
Table 1 shows the relation of practical frequency to the size of 10 2.3~3.0 0.8 1.5 2.3
hardening material and hardening layer depth.
10 3.0~4.0 0.8 1.5 2.1
Table 2 shows the relation of total hardening layer depth to
frequency and power density. 3 2.3~3.0 1.5 2.3 2.6

3 3.0~4.0 0.8 2.1 2.5

3 4.0~5.0 0.8 1.5 2.1

1 5.0~6.0 0.8 1.5 2.0

1 6.0~9.0 0.8 1.5 2.0

※(1) kW is the maximum value of meter reading during heating.
(2) Lower frequency is used for bigger hardening depth.
(3) Low power density is better to be used when there is limitation in
power generator.
(4) Histologically this can be expected the best result.
(5) This is adopted in order to use power capacity of generator
effectively and increase productivity.

4
 (2) Calculation of generator’s power capacity Table 3: Penetration depth of frequency
1) Hardening depth and length: Hardening depth means total
hardening layer depth. Calculated depth Practial depth
2) Heating time: figure out from processing tact 1kHz 15mm 20mm
3) Material
4) Shape and size 3kHz 10mm 2mm
5) Heating temperature: change according to the temperature of 5kHz 7.6mm 9mm
material such as cold material or warm material
Decision of capacity 7kHz 6.4mm 7.6mm
a) Calculate the weight of heating part 10kHz 5.4mm 6.5mm
b) Calculate the net absorbed power
c) Multiply the coefficient of heat loss 15kHz 4.4mm 5.3mm
d) Divide by heating time 20kHz 3.8mm 4.7mm

《Exercise》 30kHz 3.1mm 3.7mm

How much power capacity kW is required for RF generator to 60kHz 2.2mm 2.6mm
make harden the round bar work-piece ofφ25 in diameter, 50mm
in length and S45C material, and to obtain 1.5 mm hardening 100kHz 1.7mm 2mm
depth (total hardening layer depth) from the surface in all the 200kHz 1.2mm 1.4mm
circumference along 50 mm length by heating 2 seconds ?
350kHz 0.9mm 1.1mm
a: Weight of heating part 400kHz 0.85mm 1mm
W = π×r2 ×h×Specific gravity
These figures of depth are for reference, because practically depth differs
π= 3.14 a little according to the shape of work-piece, etc.
Specific gravity (iron) = 7.8
r = Radius
h = Length (4) Combined analysis of electro-magnetic field and heat
Calculation conduction
2.5 2 2.2 2 The researches and developments of electro-magnetic field and
W = 3.142 （（ ）（ ））
2 − 2 ×5×7.8
heat conduction combined analysis by computer are encouraged
= 42.861gr=0.0429kg these days, and these technologies are being applied to computer
simulation of RF induction hardening.
b: Net absorbing power
P = 4.186×Weight of heating part×Average specific heat×Heating temperature
kg 0.15 900 Fig.-6: Combined analysis of electro-magnetic field and heat conduction
4.186 kW = 1 Kcal / s
Average specific heat (iron) = 0.15
Heating temperature (RF hardening) = approx. 900℃∼1,000℃
Substitute above figures for formula P
P = 4.186×0.0429×0.15×900
= 24.24 kW/s

c: Heat loss
It is difficult to calculate accurately the heat losses such as
radiation loss, convection loss, conduction loss, circuit loss,
coupling loss between inductor and work-piece. Therefore,
practically we in DKK are used to multiply approximately three
times coefficient toward net absorbed power based on our
experimental and experienced data. In the exercise above, the
net absorbed power is 24.24 kW/s. In case of round bar
heating, magnetic coupling between inductor and work-piece is
excellent, so supposing as three times, the total output power
of generator will be 24.24×3 = 72.72 kW/s.

d: In the above exercise, heating time is 2 sec., so the

power capacity of generator will be 72.72÷2 = 36.36 kW.

(3) Choice of frequency

f = Frequency (Hz)
ρ
δ=5.03 μf
cm μ= Specific permeability (iron) = 1
ρ= specific resistance (μΩ・cm)
ρ= 115 (at 900℃)

5
RF Induction Tempering
RF induction tempering is taking precedence of conventional Table 4: Choice of frequency for high temperature tempering
electric furnace tempering in the next process of RF induction
Frequency
hardening, because of its short time heating and excellent working Dimension Tempering Vacuum tube oscillator or
Transistor inverter or
efficiency. (Diameter) temperature Commercial static generator transister inverter
φmm ℃ frequency (Thyristor inverter ) kHz
In RF induction tempering system, the RF power generator and 50,60Hz kHz 3kHz 10kHz 20~100 Over 100
inductor for hardening system can be used in some cases, but can
not be used in other cases depending upon the shape of heating 3~6 640 A A
work-piece or hardening layer depth as shown below.
6~12 640 A A
(1) Use same generator and inductor.
(2) Use different (lower frequency) generator and same 12~25 370 A A B B
inductor.
12~25 640 A A A B B
(3) Use largely different (rather lower frequency)
generator and completely different inductor. 25~50 370 B B A A C C
Table 4 shows the choice of frequency for high temperature
25~50 640 A A B C C
tempering. For tempering, it is better to choose approximately 1/10
frequency than that of hardening. Table 5 shows the electric power 50~150 370 A A B B
density required for tempering.
50~150 640 A A B
Conventionally, a hardened work-piece used to be tempered in
electric furnace for 1∼2 hours on purpose of stabilizing hardening Over 150 640 A A B
microstructure and removing residual stress. It used to be
considered that the tempering time is better to be longer, however, ※A: The best frequency B: Suitable frequency C: Proper frequency
Tempering temperature 640℃: Temperature range 426-704℃
it is demonstrated that by raising tempering temperature, the
Tempering temperature 370℃: Temperature range 149-426℃
insufficient effect caused by short time tempering can be
supplemented sufficiently. To obtain the necessary hardness by
tempering, the relation between tempering time and temperature is Table 5: Electric power density required for induction tempering
shown in the formula bellow.
Tempering temperature range
Frequency
(Hz) 149~426℃ 426~704℃
T1 + 273 log t2 + C
=
T2 + 273 log t1 + C 60 9.3 W/cm2 23 W/cm2

180 7.8 W/cm2 22 W/cm2

T1・ T2: tempering temperature, t・

1 t2: tempering time, C: a constant 1,000 6.2 W/cm2 19 W/cm2
decided by carbon percentage (C = 16 in case 0.45 ％, C = 15.4 in
3,000 4.7 W/cm2 16 W/cm2
case 0.40％)
10,000 3.1 W/cm2 12 W/cm2
This formula means that in case of tempering steel work-piece,
the effect, which is obtained from the condition of temperature
T1 and time t1, equals with that of temperature T2 and time t2. This
formula is used to know approximate tempering temperature, Fig.-7: Relation between tempering time and hardness
therefore to know the best condition, it is required to examine
70
accurately around the temperature obtained from the formula.
Conventionally in RF induction tempering, the method, which Material S50C
60
controls and manages heating time and output power (voltage) has
Rockwell hardness (HRC)

been normally adopted, however these days it is making a step 50

toward the method, which measures and manages tempering
temperature directly. 40
Induction tempering 5s
30
Induction tempering 60s

20
Furnace tempering 1h
10

0
100 200 300 400 500 600
Tempering temperature (℃)

6
 Composition of RF Induction Hardening and Tempering Equipment
The RF induction hardening and tempering equipment is generally composed of machines and apparatus bellow. This is the
case of Constant Velocity Joint hardening and tempering equipment in full automatic line.
Fig.-8: Composition drawing of equipment

Cooling water intake 25A(2500H) Cooling water intake 25A(500H)

11,400

3,500 600 1,600 1,500 1,600 1,000

300 700 600

100
Cooling
tank Cooling water

1,800
Quenching

1,700
Hydraulic
2,000

Air cooling type tank water tank

chiller unit unit
(Inside the pit) (Inside the pit)
Pump area

600

800
1,900 850
800
800

deionizer
Water

1,200

1,000
240kW 50kW
Transformer

receiving

Control panel Generator Generator

Power
panel
1,450

(for hardening (for tempering)

1,000
shaft/groove)

Primary power

1,750

1,050
supply ferminal
2,100

C T
3φ400V500Hz Scrubber C T C T
or.3φ3300V
（    ） 3φ6600V
Shaft hardening Groove hardening Tempering

350
Hardening/tempering machine
Flow
Conveyer direction
7,500
Conveyer Shaft sub- Groove sub- Air supply intake 20A(1000H)
operation panel operation panel 4kg/cm2 150Î/mm
Main operation panel Tempering sub-operation panel
〔Operator's side〕

(1) Power receiving panel

This is the panel for receiving primary power that is composed of
mainly transformer, NFB, voltmeter and ammeter etc. (Sometimes
this panel and RF generator use same frame depending upon design
philosophy.)

(1) Power receiving panel

7
(2) RF generator (Oscillator)
The RF generator is composed of generator main body, matching
circuit, duct for output cable, current transformer, water deionizer .
(The matching circuit is sometimes installed in generator.)
DKK manufactures various kinds of generators, which could be
applied to any kinds of customer’ s requirement.
DKK is prepared detailed specifications and standards for each
kind of generator.
※ The deionizer is equipped in the main body of all the generators
if they need it.

(2) Generator (Ex. 250kW Transistor Inverter)

Table 6: Comparison table (of DKK generators)

Types Electric motor Vacuum tube oscillator Statistic generator Transistor inverter
［DKK type］ generator (Thyristor Inverter)
Items 〔MG〕 〔VT〕 〔SG〕 〔TG, PTG〕
Frequency 1~10kHz 20~500kHz 500Hz~10kHz 300Hz~300kHz
Single output power 10~600kW 2~750kW 500~3,000kW 5~1,000kW
Frequency fluctuation Constant Fluctuating when self-oscillation (1) Constant,(2) Fluctuating (1) Constant,(2) Fluctuating
Power adjustment Exciting voltage →Output voltage Anode voltage (1) DC voltage,(2) Frequency (1) DC voltage,(2)DC current
Frequency conversion efficiency 70~83% 65~70% 75~92% 75~95%
Consumable parts Bearing Vacuum tube – –
Floor space Large Middle Small Small
Repair and replacement Long time Short time Short time Short time
Parallel operation Available Not available Not available Not available
Repair and replacement Much Much Small Small
Hardening depth 3~10mm 1~3mm 3~10mm 1~10mm

(3) Hardening Machine and/or Tempering Machine

This machine is composed of hardening station and/or
tempering station, and lift and carrier equipment, which conveys
work-pieces to hardening station and/or tempering station and
holds, moves and rotates work-pieces one by one. This machine is
roughly divided into automatic type and manual type, and the types
are chosen depending upon output, production system and
production process.
DKK produces optional machines, which have picture display in
NC control panel or ACC (Automatic Coil Changer) equipment
depending upon customer’ s request.

(3) Hardening/Tempering machine (Ex. CVJ full automatic hardening/tempering machine)

Fig.-9: Graphic panel (Ex. CVJ full automatic hardening /tempering machine)

RF Hardening/Tempering Machine
Inductor automatic Shaft hardening process Groove hardening process
setting device Tempering process All original point
Transfer loader(Ⅱ)
Locator Upper center Upper center
Inductor
tor Work

,,
yy
uc Tur n-over
ABC Ind transfer ratation

,y y,yy
,,
loader

yy
,,
,
y
M
Inductor

jacket
Periphery

Turn-over loader Work

,,
yy
,
y y,
,,
yy
rotation Temperature detecting device

Work distinction
pe
Inductor
Cooling jacket

ca work table
Es Transfer loader(Ⅰ) Work Work Slider
rotation table
(Transfer)
Cooling
After cooling
M work table
M Lower Cooling
Full work Work detection Lower center Lower center center Full work

8
 (4) Control Panel and Operation Panel
Control panel is normally of self-supported type and has built-in
sequence controller and microcomputer. The total control of the
system is done here.
Operation panel is normally attached in hardening machine, and
the setting of hardening condition and each movement of the
machine are operated here.
Operation panel is occasionally divided into main operation panel
and auxiliary operation panel according to the necessity, and
sometimes installed a graphic panel, which displays processing
progress for easy monitoring and enables to communicate with PC.

(4)-1; Control panel (Ex. In communication with PC)

(4)-2; Main operation panel (Ex. DPL series/with monitoring display) (4)-3; Sub-operation panel

(5) Heating Inductor and Inductor Holder (Cf. Fig. 14,15)

A heating inductor is the device, which induces RF current in the
heating portion of work-piece, and there are various types in heating
inductor to fit various shapes of heating portion of work-piece. (Cf.
Fig. 15)
An inductor holder is located between RF current transformer
and heating inductor and there are bolt-clamped type and lever
clamped type etc in the holder. (Cf. Construction and example of
devices for RF heat processing)

(6) Cooling/Quenching Water Circulating Equipment

Cooling water is used for cooling RF generator, current
transformer and heating inductor, and quenching water (liquid) is
used for hardening. For quenching water tank, it is needless to say
that the managing of water volume, water pressure and temperature
of quenching water is required and in case of using hardening
cracks preventing coolant, the managing of density is also
important. Typical piping schematic diagrams of cooling and (6); Cooling (quenching) water circulating equipment
quenching water circulating equipments are shown in Fig. 10,11,12.

(7) Other attached Equipments

1) Hardening/Tempering Condition Setting and Supervising
Display Equipment (DPL series)
On the liquid crystal touch panel display, hardening/tempering
condition can be set by a touch, and upper and lower limit
supervisory functions of each setting value are interlocked.
This equipment is developed by DKK for hardening/tempering
equipment, and is unrivaled in operativeness. (7)-1; Hardening condition setting panel (DPL series monitor display equipment)
Communication with PC is also available by request.

9
2) Hardening/Tempering Temperature Control Equipment
This equipment controls heating temperature of hardening or
tempering, and the temperature is measured generally by radiation
thermometer, which is normally attached a recorder.
By interlocking RF generator with this equipment, PID control of
keeping hardening/tempering temperature at a constant level is
also available.

3) Automatic Coil (Inductor) Change Equipment (ACC)

(7)-2: Hardening/tempering temperature control equipment (Ex. Included in the RF tempering equipment)
This is the highest-level ACC equipment developed based upon
abundant supply records in many years, and completed with high (7)-3-1: ACC mechanism/No.1
technology.
ACC mechanism/No.1 (Inside arrangement/Slide/Automatic selection system)
This equipment clears all the performances required for RF Transfer type
induction heating inductor such as reliable clamp (electrical Clamp
connection and water flow) with holder, static accuracy, dynamic
accuracy, repeatability and durability.

Inductor
Inside arrangement Slide type

Robot type Capacity: 3 sets

Installed in single shot hardening machine for constant velocity joint

ACC
Turn table type (7)-3-1: ACC mechanism/No.2

ACC mechanism/No.2 (Inside arrangement/Turn table/Automatic selection system)

Index table type
Slide type Index tabie

Outside arrangement
Robot type Inductor

4) Heating Electric Power Amount Control Equipment

This equipment controls Electric power amount, which is the
product of electric power and heating time, at a constant level. Capacity: 4 sets 
Installed in NC small parts shaft hardening machine
5) Non-destructive Eddy Current Inspection Equipment
This equipment is used for the inspection of hardness/hardened-
layer and hardening crack by magnetizing a work-piece, and
enables to inspect all the work-pieces and to eject defective work-
pieces automatically by installing this equipment in the system.

(7)-5: Non-destructive Eddy Current Inspection Equipment

10
 Cooling/Quenching Water Circulating Schematic Diagram
Fig.-10: Quenching water tank

Flow switch

Flow switch

(User’s scope of work)

Industrial water
Current transformer Oscillator

Flowmeter
Electric valve

Heating inductor M

Return
tank
Heat exchanger
Pump

Temperature sensor
P Temperature controller
P Level switch
Non-return valve

Heater
Return pump

Quenching water tank

Fig.-11: Quenching water tank and cooling water tank

Flow switch

Flow switch

(User’s scope of work)

Industrial water

Current transformer Oscillator

Electric valve
Flowmeter

Electric valve
Temperature controller

Heating inductor M

Return
tank Heat exchanger
Heat exchanger
Pump

Pump
Temperature sensor

Temperature sensor

P P
P Level switch Level switch
Non-return valve
Heater

Return pump

Quenching water tank Cooling water tank

11
Fig.-12: Quenching water tank and cooling water tank attached with chiller unit

Flow switch

Flow switch
Oscillator Oscillator

Air-cooled chiller unit

Flow mater
Heating inductor (Water-cooled chiller
Return unit is available)
tank

Temperature sensor
Return pump Non-return valve
Electric valve
P M
Oil/water Pump
separator Level switch
Magnetic separator (Optional) P
(Optional) Temperature
Pump

P controller
Heat exchanger

Cooling water tank

Temperature sensor
Quenching water tank Heater
Level switch
(1) In case of water- cooled chiller unit is used, primary cooling water and piping works are necessary.
(2) Quenching water tank and cooling water tank are sometimes installed in the pit.
(3) Control panel is attached.
(2) Quenching water/liquid temperature
(1) Water Quality Standard Fig.-13: Effects of quenching water/liquid temperature on hardness
In induction heating equipment, cooling water is necessary
because water-cooled inductors made of copper pipe are used. The 700
water flow section is relatively small and to prevent temperature rise
of inductors, it is required to keep the inside of copper pipe in good 600
Hardness

condition for heat conduction.

Therefore, there is a certain limitation in the quality of cooling
water. 500
DKK’ s standard is as follows. Liquid Liquid
HV Symbol temperature amount
400 （℃） （cc/sec/cm2）
Table-7: Water quality standard of cooling water for induction heating equipment
30
Appearance No color 40 30
300 50
Specific resistance Below 4000Ωcm 55 20
PH value 6.5~7.5 S50C annealed maeteral
Total hardness Below 40ppm 200
0.5 1.0 1.5 2.0 2.5
Calcium hardness Below 30ppm
Magnesium hardness Below 10ppm 700
Oxygen consumption (Acid oxidation method by KMnO4) Below 2ppm
Hardness

Chlorine ion (Cl) Below 15ppm 600

Sulfuric ion (SO4) (By gravimetric method) Below 20ppm
Calcium ion (Ca2+) Below 15ppm 500
Liquid Liquid
Magnesium ion (Mg2+) Below 2ppm HV Symbol temperature amount
（℃） （cc/sec/cm2）
Total iron Below 0.3ppm 400
30
Dissolved iron ion Below 0.03ppm 40 30
50
Vaporized residue Below 120ppm 300 55 20
Above shown are standard values. Almost all kinds of industrial waters are SCM435H material
within the value. Even the case of over limitation, but small difference, 200
there is no problem using the water. 0.5 1.0 1.5 2.0 2.5
Distance form surface mm
From the figure above, it is generally effective to keep quenching water
temperature 30℃~40℃ for preventing hardening crack.
12
 Structures and Examples of Requisites for RF Heat Processing (Hardening/Tempering)
For RF induction hardening/tempering, followings are required Fig.-14: Relative connection of RF power units
other than RF generator and hardening/tempering machine.
(1) Heating inductor and cooling jacket
(2) Jig
(e) (c)
(3) Inductor holder Output lead Inductor holder
(4) Current transformer Power source Work-piece

, , ,
(5) Output lead (a)
(d) Heating
These are connected relatively as shown in Fig. 14. RF inductor

,,
yy
Current

, ,,
generator
transformer

,,
yy
(b)Jig

(1) Outline of Heating Inductor
Heating inductor, which induces RF current in the heating portion
of a work-piece, is a coil made of 2∼10mm copper pipe in one or
two turn in case of simple type, and cooled with water flow inside
the pipe. Inserting a work-piece into the circular inductor, which is
energized with RF current, the work-piece is heated.
In this case, the clearance between work-piece and heating inductor
affects the power efficiency, and as closer the efficiency is better.
Actually 1∼5 mm clearance is selected considering fluctuation of
steadiness by expansion and deformation of scorchingly heated
work-piece, and mechanical rotation.
In actual surface hardening, the quality of hardening is affected with
RF electric power, frequency and quenching liquid etc, however,
the shape of inductor is the most effective one. In manufacturing
inductors using copper material, silver blazing works are most
important.
,,,
In the case of simple shaped work-piece, the design of inductor is
easy, however, in the case of complicated shaped work-piece, to
make it harden effectively, the design of inductor is done reflecting
the experienced know-how.
For the purpose of giving strong heating partially, magnetizing
substances such as silicon steel laminates or ferrite cores are
arranged at the portion.
DKK’ s heating inductors except for special ones are generally
manufactured by machining and finished after brazing (normally
silver brazing) with jig, which is prepared beforehand, and
inspected with inspection jig to keep the accuracy strictly. For
changing heating inductor, setting jig is available. These days, some
of the inductors for scanning hardening are manufactured by only
machining and not using silver brazing.

13
Fig.-15: Application examples of practical heating inductors

Heating work-piece

,,,
Water

,,,
Heating inductor Heating inductor Heating inductor
water Heating

,,, yy
,,
Water
Heating layer work-piece

,,, y,y,y,y,yy
,, ,
y ,
y
,,, ,,
yy ,
y ,
y
Heating
layer

,,,
,,,
Hardening
layer y,y,yy
,,y,y,
,,,
Quenching water
Quenching Hardening layer
Hardening layer water
Heating work-piece
(Ball-stud)
Quenching water

(1) Heating inductor for continuous scanning (2) Heating inductor for inside scanning (3) Heating inductor for ball-stud

Water Heating work-piece

(Saw tooth)
Heating inductor
Hardening layer
Water
Heating inductor
Heating inductor

yyy
,,,
y
,yy
,,
,,,
yyy
Quenching water
Water Water

,,,yyy
yyy,,,
Moving
Hardening layer
Oil-level

Quenching water Heating work-piece

(Crankshaft)
Heating work-piece

(4) Heating inductor for traveling long plane (5) Heating inductor for saw tooth (6) Split type heating inductor for crankshaft

,yy,y,y,y,y,y,y,y,y,y,y,y,y,
y,y,y,y,y,y,y,y,y,y,y,y,y,y,
Heating work-piece
Water
RF
(Gear) electric current
Heating inductor
Water (Gear)
Heating inductor
Quenching water Water
Quenching water Water
splashing hole Quenching water
Water for Insulation mica
Heating work-piece
quenching

,yy,y,y,y,y,y,y,y,y,y,y,
(Gear)

Silicon steel laminate

y,y,y,y,y,y,y,y,y,y,y,y, Water for

quenching
Silicon steel laminate Quenching water

(7) Large one gear stationary hardening heating inductor (8) Heating inductor for large one gear scanning (9) Heating inductor for small one gear scanning

14
 (2) Classification of heating inductor ②Various kinds of one shot inductor for shaft hardening: multi-turn inductor
Heating inductors are generally classified as follows.
①Classification by heating method
・Stationary heating inductor (one shot inductor): during
heating, inductor and work-piece are in same position
・Scanning heating inductor: during heating, inductor or work-
piece travels
・Direct heating inductor: direct resistance and induction heating
②Classification by copper material processing method
・Copper plate inductor: processed with lathe, shaper etc
・Pipe inductor: processed of round pipe, square pipe etc
③Classification by heating inductor and work-piece position
・Outside heating inductor
・Inside heating inductor
・Plane heating inductor

(3) Examples of Heating inductor

①One shot heating inductor for gear/sprocket hardening: single turn ③Semicircular heating inductor for crankshaft hardening
inductor

Brazing

, , , , , ,
Heating work-piece About 5m/m
(Gear)

,,,,,,,, ,,,,
t2 Copper
plate

,,,, Water holeφ1.5~2.0

Jig
④Split type heating inductor

《Features》
This is a typical one shot heating inductor and has water-
splashing holes.

15
 ⑤Scanning heating inductor for axle shaft: splash cooling water from Pipe inductor and jacket
heating inductor
Pipe diameterφ3∼12
Hardening layer Heating inductor
Quenching

,,
,, ,,
,,
water jacket

Hardening layer

Heating work-piece
Heating layer

,,,, ,,,
Heating inductor

,,
Copper plate inductor
and jacket Quenching

,,,, ,,,,
water jacket

Heating layer

,,,,,,,
Brazing
Inductor
cooling pipe
Hardening layer

Water holeφ1.6~2.2 ⑦Inside traveling heating inductor for tri-pot housing inside hardening

Heating work-piece

Hardening layer

《Feature》
This is suitable for long shaped work-pieces. Output power is
smaller than that of one shot heating.

⑥Traveling shaft heating inductor: Heated with heating inductor and

quenched with cooling water from jacket.
DKK PAT.

⑧Tooth surface traveling heating inductor for single gear tooth hardening

DKK PAT.

16
 ⑨Plane heating inductor for clutch-hub synchronizer flat side hardening A copper pipe inductor is manufactured using annealed round
copper pipe, after filling sand in the pipe, winding around jig. (Pipe
inductor)

φ15∼
φ3∼10

Wrapping jig

Copper pipe

Instead of using round pipe, another type of inductor is

⑩Solenoid type heating inductor for hardening inside diameter of hollow part manufactured using copper plate or round bar, after processing the
material with lathe into circular rings, connecting them to compose
a multi-turn inductor. (Copper plate inductor)

⑬Direct resistance heating inductor for rack steering teeth side hardening

⑪Hair-pin heating inductor

Hardening layer

,yy,y,y,y,y,y,y,y,,y,,y,,y,,y,,y,,
Rack steering

y,y,y,y,y,y,y,y,y,y,
Quenching water Heating inductor
RF
generator

《Feature》
Partial heating/hardening of a work-piece is possible.

⑫Inside heating inductor for internal gear hardening

Section

Hardening layer

《Principle》
When RF electric current is supplied to the teeth side of work-
piece through quenching water jacket, the current flows mainly on
the surface of teeth and current density at the tips of teeth becomes
bigger more than botton side. As a result of, the teeth side can be
heated more than botton side.
The heating portion becomes a part of the inductor, and the
portion itself can be inductively heated. And also because of edge
effect (the magnetic flux is concentrated at the edge), electric
current flows mainly at the edge of the teeth.

17
 ⑭Single-shot heating inductor for shaft hardening Single-shot heating inductor and quenching water jacket
Structure of quenching water jacket
Half-cylindrical (Horseshoe-shaped) type: fixed
Box type: fixed

t3∼t6(Copper plate)
Heating work-piece t2(Copper plate)

,yy,,,y,y,,,,,,,,,
, ,
y,,y,,,,, , , ,
Heating inductor
Lead connection of inductor
RF generator

RF generator
Heating work-piece

Heating work-piece

The material of quenching water jacket can be substituted

Bakelite or vinyl chloride materials for copper plate.

yyyy
,,,,
,,,,
yyyy
《Feature》 t3∼6
Suitable for long and uneven shaft hardening and the deformation (Copper, Brass, Bakelite)

,
y,,
y, ,
by hardening is smaller than that of scanning. Although large RF φt6∼12
(Square pipe or round pipe)

,,
y ,,
y ,
power is required, processing tact is shorter than that of
Heating inductor
scanning.

, , ,
Quenching jacket
(fixed)

⑮Single-shot heating inductor for R portion of shaft

,
y,y
,,,,
yyyy, , Forward Backward

Heating work-piece
φ1.5∼2.0 ,y
y ,
,,,,
yyyy
Silicon steel laminate
Dust core
Oken-core

By using magnetic flux concentrator such as dust core or Oken-core

on the inductor, heating efficiency increases.

⑰Protection of heating inductor

As large electric current flows in heating inductor, exothermic
measures and electrical insulation measures are required for
protection.
Exothermic measures
(1) Make sufficient flow of cooling water to heating inductor.
(2) Keep cooling water temperature below 35℃.
Insulation measures
Practical measures are shown below. Each measure has both
⑯Special type single-shot heating inductor merits and demerits and is applied on a case-by-case basis.
《Examples》
(1) Wrap with glass tape or vinyl tape etc.
(2) Treat with alumina coating etc.
(3) Mould with epoxy resin etc.
(4) Mould with refractory.
(5) Treat with Teflon coating etc.
Electric measures
(1) Detect a touch of inductor with work-piece

18
 (4) Examples of Quenching water Jacket (5) Inductor not using current transformer

①Box type quenching water jacket ①Multi-turn inductors such as for RF induction tempering etc

②Ring type quenching water jacket

②Tempering inductor

③Jacket and inductor integrated type for scanning hardening

(6) Jigs
(Role of jig)
It is used for holding a work-piece, usually for a work-piece
rotation.
(Material)
Ⅰ) Bras: It is easy to be processed but also easy to be worn
out.
Ⅱ) SS material: It is easy to be processed but also easy to be
rusted and worn out.
Ⅲ) Stainless: Austenite stainless is less RF induced and free
from rusting.
Ⅳ) Silicon nitride: It is not RF induced but hardly processed
and expensive.
Ⅴ) Copper: Easy to be worn out but because of it’ s high heat
conductivity, it is better for heat absorber.

19
(7) Inductor-holder
(Role of inductor-holder)
This is used to connect inductor with current transformer.
Various types of holders are prepared to conform to the types of 45 100
inductors and current transformers. Each holder is designed so as
to set up inductor easily. The shorter holder in length is better in
efficiency.

25

55
80
①Bolt-fastened type inductor-holder

M6 plate screw
145 C・T installation side
16.5 100

10φcopper pipe
4・hexagon bolt
M8×50

100
70
②Transformed lever clamp type inductor-holder
2TPM coupler
connection

④Inserting type inductor-holder

③Lever clamp type inductor-holder

20
 RF Hardening Adopting Manual

Table 8: Practical decision of RF hardening specification

Hardening hardness Hardening depth Maximum
Steel kind・Symbol A(Water) B(Oil) mm hardening depth Preprocess
HRC HV HS HRC HV HS A(Water) B(Oil) (Water)
Carbon steel for machine structure
S 35 C 40∼50 390∼510 54∼67 35∼45 350∼45048∼60 1.0∼2.0 1.0∼2.0 4.0 Refining
ditto S 40 C 45∼55 450∼600 60∼74 40∼50 390∼51054∼67 1.0∼2.0 1.0∼2.0 4.0 ditto
ditto S 45 C 50∼60 510∼700 67∼81 43∼53 420∼56057∼71 0.8∼1.5 1.0∼2.0 4.0 Refining or normalizing
ditto S 50 C 55∼62 600∼750 74∼85 45∼55 450∼60060∼74 0.8∼1.5 1.0∼2.0 5.0 ditto
ditto S 55 C 58∼63 650∼770 78∼87 50∼60 510∼70067∼81 0.8∼1.5 1.0∼2.0 5.0 ditto
Nickel-chrome steel SNC 236 45∼55 450∼600 60∼74 40∼50 390∼51054∼67 1.0∼1.8 1.0∼1.8 6.0 Refining
(SNC 1)
ditto SNC 631 42∼52 380∼540 56∼69 37∼47 360∼470 50∼63 1.0∼1.8 1.0∼1.8 6.0 ditto
(SNC 2)
ditto SNC 836 50∼60 510∼700 67∼81 45∼55 450∼600 60∼74 1.0∼1.8 1.0∼1.8 6.0 ditto
(SNC 3)
Nickel-chrome molybdenum steel SNCM437 50∼58 510∼650 67∼78 45∼53 450∼560 60∼71 1.0∼1.8 1.0∼1.8 8.0 ditto
(SMCN 8)
ditto SNCM447 55∼63 600∼770 74∼87 50∼58 510∼650 67∼78 1.0∼1.8 1.0∼1.8 8.0 ditto
(SMCN 9)
Chrome steel SCr 430 50∼60 510∼700 67∼81 45∼55 450∼600 60∼74 1.0∼1.8 1.0∼1.8 6.0 ditto
(SCr 2)
ditto SCr 435 50∼60 510∼700 67∼81 45∼55 450∼600 60∼74 1.0∼1.8 1.0∼1.8 6.0 ditto
(SCr 3)
ditto SCr 440 55∼63 600∼770 74∼87 50∼58 510∼650 67∼78 1.0∼1.8 1.0∼1.8 6.0 ditto
(SCr 4)
ditto SCr 445 55∼63 600∼770 74∼87 50∼58 510∼650 67∼78 1.0∼1.8 1.0∼1.8 6.0 ditto
(SCr 5)
Chrome molybdenum steel SCM 430 50∼60 510∼700 67∼81 45∼55 450∼600 60∼74 1.0∼1.8 1.0∼1.8 8.0 ditto
(SCM 1)
ditto SCM 432 50∼60 510∼700 67∼81 45∼55 450∼600 60∼74 1.0∼1.8 1.0∼1.8 8.0 ditto
(SCM 2)
ditto SCM 435 52∼62 540∼750 69∼85 47∼57 470∼630 63∼76 1.0∼1.8 1.0∼1.8 8.0 ditto
(SCM 3)
ditto SCM 440 55∼65 600∼830 74∼91 50∼60 510∼700 67∼81 1.0∼1.8 1.0∼1.8 8.0 ditto
(SCM 4)
Heat resistant steel SUH3 50∼60 510∼700 67∼81 45∼55 450∼600 60∼74 1.0∼2.0 1.0∼2.0 − ditto
Stainless steel SUS420J1 30∼40 300∼390 42∼54 25∼35 270∼350 38∼48 1.0∼2.0 1.0∼2.0 − Refining or normalizing
ditto SUS420J2 45∼55 450∼600 60∼74 40∼50 390∼510 54∼67 1.0∼2.0 1.0∼2.0 − ditto
Carbon tool steel SK2 58∼63 650∼770 78∼87 53∼58 560∼650 71∼78 1.0∼1.8 1.0∼1.8 5.0 ditto
ditto SK5 58∼63 650∼770 78∼87 53∼58 560∼650 71∼78 1.0∼1.8 1.0∼1.8 5.0 ditto
ditto SK7 58∼63 650∼770 78∼87 53∼58 560∼650 71∼78 1.0∼1.8 1.0∼1.8 5.0 ditto
Ball graphite cast iron FCD 55 50∼60 510∼700 67∼81 45∼55 450∼600 60∼74 1.0∼2.0 1.0∼2.0 − Annealing
Perlite malleable cast iron FCMP 50 50∼60 510∼700 67∼81 45∼55 450∼600 60∼74 1.0∼1.8 1.0∼1.8 − ditto
A is for simple shaped work-pieces such as shaft, pin etc.
B is for complicated shaped work-pieces such as housing, shift-fork etc.
The figures in the table above are for the desirable hardening, which the microstructures on the surface are even and wearability is excellent.
The suitable hardening depth “d” for the desirable fatigue limitation is calculated as, assuming the diameter of work-piece “D”, d = 0.15D.

Fig.-16: General confirmation for RF hardening

Hardening crack
inspection
Selection of coolant Selection of kHz Selection of heating inductor
Magnetic (Water, Oil,Water- suitable frequency   For one-shot hardening
defectoscope etc miscible liquid)   For scanning
Temperature,   For plane hardening
Water volume,   For inside hardening
Hardening Pressure Position of inductor
Design of construction
work

Distortion inspection Hardness measurement Setting of heating Setting of jig which suits
Depth measurement  electric power, for processing work-piece
Hardening microstructure  heating time (Setting position etc)
inspection

21
Table-9: HRC hardness approximation conversion table for steel
Brinell hardness Rockwell superficial hardness
10mm ball/3000kg load Rockwell hardness special Brale penetrator
Rockwell Vickers Shore
A scale load B scale load D scale load 15-N 30-N 45-N
C scale Standard Hult-gren Tungsten
60kg 100kg 100kg scale scale scale
hardness hardness carbide hardness
Brale diameter1/16in Brale load load load
ball ball ball
penetrator ball penetrator 15kg 30kg 45kg
68 940 - - - 85.6 - 76.9 93.2 84.4 75.4 97
67 900 - - - 85.0 - 76.1 92.9 83.6 74.2 95
66 865 - - - 84.5 - 75.4 92.5 82.8 73.3 92
65 832 - - 739 83.9 - 74.5 92.2 81.9 72.0 91
64 800 - - 722 83.4 - 73.8 91.8 81.1 71.0 88
63 772 - - 705 82.8 - 73.0 91.4 80.1 69.9 87
62 746 - - 688 82.3 - 72.2 91.1 79.3 68.8 85
61 720 - - 670 81.8 - 71.5 90.7 78.4 67.7 83
60 697 - 613 654 81.2 - 70.7 90.2 77.5 66.6 81
59 674 - 599 634 80.7 - 69.9 89.8 76.6 65.5 80
58 653 - 587 615 80.1 - 69.2 89.3 75.7 64.3 78
57 633 - 575 595 79.6 - 68.5 88.9 74.8 63.2 76
56 613 - 561 577 79.0 - 67.7 88.3 73.9 62.0 75
55 595 - 546 560 78.5 - 66.9 87.9 73.0 60.9 74
54 577 - 534 543 78.0 - 66.1 87.4 72.0 59.8 72
53 560 - 519 525 77.4 - 65.4 86.9 71.2 58.6 71
52 544 500 508 512 76.8 - 64.6 86.4 70.2 57.4 69
51 528 487 494 496 76.3 - 63.8 85.9 69.4 56.1 68
50 513 475 481 481 75.9 - 63.1 85.5 68.5 55.0 67
49 498 464 469 469 75.2 - 62.1 85.0 67.6 53.8 66
48 484 451 455 455 74.7 - 61.4 84.5 66.7 52.5 64
87 471 442 443 443 74.1 - 60.8 83.9 65.8 51.4 63
46 458 432 432 432 73.6 - 60.0 83.5 64.8 50.3 62
45 446 421 421 421 73.1 - 59.2 83.0 64.0 49.0 60
44 434 409 409 409 72.5 - 58.5 82.5 63.1 47.8 58
43 423 400 400 400 72.0 - 57.7 82.0 62.2 46.7 57
42 412 390 390 390 71.5 - 56.9 81.5 61.3 45.5 56
41 402 381 381 381 70.9 - 56.2 80.9 60.4 44.3 55
40 392 371 371 371 70.4 - 55.4 80.4 59.5 43.1 54
39 382 362 362 362 69.9 - 54.6 79.9 58.6 41.9 52
38 372 353 353 353 69.4 - 53.8 79.4 57.7 40.8 51
37 363 344 344 344 68.9 - 53.1 78.8 56.8 39.6 50
36 354 336 336 336 68.4 (109.0) 52.3 78.3 55.9 38.4 49
35 345 327 327 327 67.0 (108.5) 51.5 77.7 55.0 37.2 48
34 336 319 319 319 67.4 (108.0) 50.8 77.2 54.2 36.1 47
33 327 311 311 311 66.8 (107.5) 50.0 76.6 53.3 34.9 46
32 318 301 301 301 66.3 (107.0) 49.2 76.1 52.1 33.7 44
31 310 294 294 294 65.8 (106.0) 48.4 75.6 51.3 32.5 43
30 302 286 286 286 65.3 (105.5) 47.7 75.0 50.4 31.3 42
29 294 279 279 279 64.7 (104.5) 47.0 74.5 49.5 30.1 41
28 286 271 271 271 64.3 (104.0) 46.1 73.9 48.6 28.9 41
27 279 264 264 264 63.8 (103.0) 45.2 73.3 47.7 27.8 40
26 272 258 258 258 63.3 (102.5) 44.6 72.8 46.8 26.7 38
25 266 253 253 253 62.8 (101.3) 43.8 72.2 45.9 25.5 38
24 260 247 247 247 62.4 (101.0) 43.1 71.6 45.0 24.3 37
23 254 243 243 243 62.0 (100.0) 42.1 71.0 44.0 23.1 36
22 248 237 237 237 61.5 99.0 41.6 70.5 43.2 22.0 35
21 243 231 231 231 61.0 98.5 40.9 69.9 42.3 20.7 35
20 238 226 226 226 60.5 97.8 40.1 69.1 41.5 19.6 34
(18) 230 219 219 219 - 96.7 - - - - 33
(16) 222 212 212 212 - 95.5 - - - - 32
(14) 213 203 203 203 - 93.9 - - - - 31
(12) 204 194 194 194 - 92.3 - - - - 29
(10) 196 187 187 187 - 90.7 - - - - 28
( 8) 188 179 179 179 - 89.5 - - - - 27
( 6) 180 171 171 171 - 97.1 - - - - 26
( 4) 173 165 165 165 - 85.5 - - - - 25
( 2) 166 158 158 158 - 83.5 - - - - 24
( 0) 160 152 152 152 - 81.7 - - - - 24

22
 Trial processing and Experiment

In induction hardening/tempering, various kinds of parts such as automobile parts, construction machine parts, machine tool parts etc
are processed. We described how to decide output power and frequency of generator in the preceding clause, however in general, the
shape of each kind of parts is different, and so the method of processing is individually different. Therefore, the best way to decide output
power and frequency of generator is to be done based upon the data of trial hardening process using RF generator for the purpose. DKK
prepares trial testing equipment and inspection equipment listed in the tables bellow to meet to any kinds of customer’ s requirements.
Please refer to table 10 and 11.
※ In case we have tested upon request, we will submit the result in a report of testing method and inspection data.
For ordering a trial processing of parts, please inform us the purpose of parts used for, shape and size with drawing and processing tact.
After ordering, we need a couple of weeks for preparing heating inductor etc. We will submit the report in about one week after finishing
heating inductor etc.

Table 10: Testing equipment

Device Output
Oscillators type Frequency(kHz) Hardening machine Drive Heating method Stroke
Type (kW)
DMH-800S special
Motor Work traveling and
No. 1 MLL-250STRⅡ type VT 250 30・60・200 type hardening 800m/m
(Pulse) stationary heating
machine

DOH-800 type Oil Work traveling and

No. 2 M-40TR type VT 40 300 800m/m
hardening machine pressure stationary heating

DMH-800S type Motor Work traveling and

No. 3 MLL-120TR type VT 120 30・60・200 800m/m
hardening machine (Pulse) stationary heating

DMH-1000S type Motor Inductor traveling and

No. 4 PG-3/10-350 type SG 350 3・10 1000m/m
hardening machine (Pulse) stationary heating

Full-automatic
Hydraulic Total length
No. 5 PTG-10/20-200 type TG 200 10・20 crankshaft hardening Single-shot
pressure 1500m/m
machine

No. 6 PG-3/10-600 type SG 600 3・10

DMH-500 special
Motor Work traveling and
type hardening 500m/m
(Pulse) stationary heating
machine
No. 7 ML-750STR type VT 750 6・200

※ VT=Vacuum Tube, SG=Static Generator, TG= Transistor Inverter

Table-11: Inspection equipment

1. X-ray stress measuring equipment: Output 30kW×10mA, Parallel beam

2. Scanning electron microscope: Magnification: 30∼70000, Accelerating voltage: 20kV, Resolution: 80A

3. Automatic Vickers hardness meter: Load 1・5・20・30・50kgf, 100-power measuring microscope

4. Micro-Vickers hardness meter: Load 10∼1000gf, 200-power measuring microscope

5. Optical microscope: 50∼400-power

6. Magnetic flaw meter: Voltage 200∼220V, Magnetizing current 3000A

7. Sample inlay machine

8. Sample grinder (3 sets)

9. Sample dryer

10. Automatic cutter (2 sets)

11. Electric furnace

12. Carbon analyzer

13. Gear accuracy measuring equipment

14. Heating temperature measuring equipment (various kinds)

15. Charpy impact testing machine

※ The above equipments are equipped in the trial processing factory. We have many other RF hardening and inspection equipments in the job-shop
factory too.

23
RF hardening/tempering trial processing machine X ray stress measuring equipment

Automatic Vickers reading machine

Charpy impact testing machine

Scanning electron microscope

24
 Inquiry and Ordering Information
※ The manufacturing and installation process of DKK’s hardening/tempering equipment after receiving an order is generally as follows.

Meeting on ordering Meeting on Submit final

specification → approval drawing → approval drawing → Factory inspection → Installation → Trial operation → Commissioning

↓ ↓ ↓ ↓
Parts Manufacturing Submit hardening Submit instruction
ordering /tempering data manual

※ Please inform us following requirements on the occasion of 800mm, 1000mm, 1500mm, 2000mm)
inquiry or ordering DKK’s RF hardening/tempering equipment. One-shot hardening machine
(1) Purpose (Ex. Hardening or Tempering) Exclusive use machine
(2) Power supply Voltage/Frequency Manual machine
(3) Environment of plant Automatic machine
(4) Specification of heat processing (Please show us with drawings.) Pre-process and post process
●Name and size of work-piece Supplying equipment (Stock amount)
●Material and composition Discharging equipment (Stock amount)
●Pre-heat processing Carrier equipment (Conveyer type, Turn-table type,
●Hardness of material Lift and carrier type, etc.)
●Portion of hardening Drive
●Hardening hardness Hydraulic pressure
●Hardening depth layer Pneumatic pressure
●Distortion before and after hardening Motor
●Processing tact and processing amount Etc.
※ In case there are many kinds of work-pieces, please inform ●Control panel and operation panel
us the pertinent ones, which shall be the estimation standard of Sequence controller type (Manufacturer name)
generator’s output power.（The pertinent ones mean the wark- Display equipment
pieces, which are maximum, minimum in size and largest in Etc.
processing/production number.） ●Cooling water circulation equipment
(5) Specification of equipment Air-cooling/water-cooling chiller (refrigerator)
●RF generator(Vacuum tube type/ Thyristor type/Transistor type) Quenching water circulating equipment
Output kW Cooling water circulating equipment for machine
Frequency kHz Other attached equipments (Magnetic separator, Oil/water
●Number of processing stages separator, Flow meter)
●Hardening machine ●Heating inductor and jig
Standard machine Number
Vertical type scanning hardening machine (500mm, ●Other attached equipments

DKK’s RF Induction Heating Equipments Manufacturing/Sales Items

※ DKK accepts orders of equipments below and RF generators for semi-conductor production use etc besides the RF hardening/tempering equipment

Melting Heat processing（Job-shop） Billet heating Solderring Pipe welding

Brazing

Hardening/ Annealing
Temperring

,,,,,,
,,,,,,
,,,,,,
,,,,,,
・Seel ・Automobile parts ・Iron ・Byte（Cutting tool） ・Water tube
Adopted material and

・Automobile
・Stainress ・Motorcycle parts ・Aluminum ・Automobile parts ・Gas tube
parts
・Copper ・Parts for construction ・Brass ・Motercycle parts ・Erectric wire tube
parts

・Welded pipe
・Gold/Silver machine ・Stainress ・Bicycle parts ・Square pipe
・Forged parts
・Titanium ・Parts for industrial ・Others ・Aluminum pipe
・Electronic machine ・Stainless pipe
material ・Parts for machine tool ・Copper/Titanium pipe
25
Head Office: RF Application Equip. Sales Dep.
Shin Tokyo Bldg., 3-3-1 Marunouchi, Chiyoda-ku, Tokyo 100-0005, Japan
Tel 03-3216-9433∼4, Fax 03-3216-1669
Osaka Office
18-38, Toyotsu-cho, Suita-shi 564-0051
Tel 06-6378-0162, Fax 06-6378-0163
Atsugi Plant（RF Administration）
4052-1, Nakatsu, Aikawa-machi, Aiko-gun, Kanagawa 243-0303, Japan
Tel 046-285-1411, Fax 046-285-5302

RF Division Group Companies

Denko Techno Heat Co., Ltd
Head Office, Hamamatsu Plant: 170 Tsumori-cho Hamamatsu-City Shizuoka-Pref. 430-0815 Japan
Head Office:Tel 053-441-8451, Fax 053-441-8896
Hamamatsu Plant:Tel 053-441-8517, Fax 053-441-8896
Kariya Plant:1 Yamanota Kariya-City Aichi-Pref. 448-0812 Japan
Tel 0566-27-0750, Fax 0566-27-6394
Suzuka Plant:1820-39 Nakanoike Mikkaichi-machi Suzuka-City Mie-Pref. 513-0803 Japan
Tel 0593-82-1829, Fax 0593-82-1419
Shiga Plant:10 Satsukigaoka Minakuchi-Cho Kouga-Gun Shiga-Pref. 528-0062 Japan
Tel 0748-63-3831, Fax 0748-63-3833
Koshuha Kogyo Co., Ltd.（in DKK Atsugi Plant）
4052-1 Nakatsu Aikawa-machi Aiko-gun Kanagawa-Pref. 243-0303 Japan
Tel・Fax 046-286-1065
Denko Metallurgical Technology Co., Ltd.（in DKK Head Office）
Shin Tokyo Bldg., 3-3-1 Marunouchi, Chiyoda-ku, Tokyo 100-0005, Japan
Tel 03-3286-5233, Fax 03-3286-5270

26
 QS
Rー009

ISO9001登録
JQA-1599

2001.3.3. 000 ASP Printed in Japan