Thermal analysis of laser surface transformation hardening - optimization of process parameters

This paper deals with the optimization of process parameters for maximum productivity (given by the product of scanning velocity and cross feed) in laser transformation hardening. The process parameters considered are laser beam power, P; laser beam diameter, D-b; and the heat intensity distribution, namely, normal, bimodal, or uniform. A thermal analysis of the laser surface transformation hardening of gears was conducted (based on Jaeger's classical moving heat source method) by considering the laser beam as a moving plane (disc) heat source to establish the temperature rise distribution in the workpiece (gear) of finite width. In a recent investigation [Int. J. Heat Mass Transfer 44 (2001) 2845], the authors considered the case of a heat source with a pseudo-Gaussian (or normal) distribution of heat intensity. The analytical results were compared with the experimental results published in the literature. In laser heat treatment of steel, it is generally considered preferable to use a wider heat intensity distribution, such as uniform or bimodal, for it enables more uniform case hardening depth. In this paper, this model is extended to cover bimodal and uniform distributions and compared with the normal distribution. Scanning velocities for no surface melting and for a case hardening depth of 0.1 mm were determined for surface transformation hardening of AISI 1036 (EN 8) steel for a range of laser beam powers, P, laser beam diameters, D-b, and various heat intensity distributions. Since diffusion during the heat treatment (surface transformation hardening) process is a time dependent phenomenon, based on the literature review, an interaction time of 15 ms was taken as a basis. It is hoped that laser industry with adequate facilities available can validate the thermal analysis and subsequent optimization presented in this paper. (C) 2004 Elsevier Ltd. All rights reserved.