Visit to M/s induction heat treaters

Date:- 21.09.2019
 Visit to M/s induction heat treaters
• Visited M/s induction heat treaters as on 21.09.2019.
• Meeting with the person Wagh.
• Points discussed
• A) Max case depth for SAE 4140 up to 4 mm.
- To achieve this Need to
- Select proper machine
- Select Polymer based coolant
- Temperature and coolant settings
- Select proper processes parameters.

- Need continuous (solid) material

- Gaps may leads in cracks

 Visit to M/s induction heat treaters
• For interruptions if we plug the taps or holes with brass plugs cracks may
not get initiated.
Additional plugs fitment to
avoid cracks

• Or hardness/ case depth can be adjusted in program for particular area

• Case Depth:-

ECD:-Effective case depth ECD:-Effective case depth

TCD:-Total case depth TCD:-Total case depth

For Normalize material ECD is less For Toughened material ECD is

than TCD almost equal to TCD
 Visit to M/s induction heat treaters

Effective case depth :-

The depth where required hardness achieved.

- Case depth variation is within 0.5 mm range.

Surface hardness

- with 20% decrease in hardness.

Hardness 20 % less than surface hardness

Example :- If we Specify case depth 2.5 mm.

And hardness 60HRC
- Case depth will be within 2.25 mm to 2.75mm.
- Hardness on surface is 60 HRC where as at the end of
case depth it will be 48 HRC.
 Visit to M/s induction heat treaters

• Finalizing Case depth:-

- we need to add grinding allowance in to the final case depth.

- Also need to consider process variation of 0.5 mm.

- And maximum bend in material after hardening (as per induction hardening
Person) the max. possible bend is 0.1 to 0.2 mm.

- Also need to consider the cut off hardness at the end of case depth.

- Position of tapping also need to consider while

finalizing the case depth.
 Visit to M/s induction heat treaters

• Finalizing Inspection procedure:-

- For initial stage we have to give one extra piece as per our machined pins
per lot for inspection and destructive testing.
-Test includes
1) Hardness testing (Rockwell hardness).
2) Vickers hardness
3) Case depth
4) Microstructure
5) MPI Test
- M/s Induction hardening will carry these tests for each lot which
will included in process sheet. But for extra samples drawn or
required by EPML will be chargeable.
 Visit to M/s induction heat treaters

• Finalizing procedure:-
- For induction hardening SAE 4140 material is also ok.
- Need to toughen the material up to 270 ~300 BHN Measurement
must be in BHN for precise readings.
- Need to finalize the proper batch Or feed to induction hardening
for uniformity in hardness. Less destructive testing's. And to
minimize the setup changes.
-There must be less variation in rough machining to achieve proper
case depth in hardness
 Visit to M/s induction heat treaters

• Finalizing procedure :-
- For final grinding machining allowance is 0.6mm radius.
- Need to check whether the
machining (Cutting/milling/drilling/tapping) is possible for
toughened pins.
-As per machining supplier, Material cutting,drilling,tapping
operations are not possible on toughened material.
- In that case need to add Toughening procedure after rough
machining and toughened material procurement not possible.
 Process flow chart

Material testing Materiel cutting

Material
for confirmation as per required Rough machining Stage Inspection
Procurement
of SAE:4140 lengths

Send material for Hardness testing

Sample test and Induction in BHN
hardening in Toughening
approval hardening
proper batches 270~300 BHN

Inspect the pins 100%

Hardness test by for bend during Final finishing and dimensional
Rockwell 100% for Final grinding the operation and cleaning inspection
each component for excess bend operations And hardness
mark as rejection testing

Binning by Receipt at EPML Dispatch along

Proper packaging
ensuring proper Cross check by with invoice and
end GRIR inspection and
by applying rust
preservation QC preventive
preparation test reports