Finite element simulations of induction hardening for crankshafts

In a truck the crankshaft is the key component and the durability of said component is important to ensure the quality of the engine and the truck as a whole. In order to achieve the desired durability of the crankshaft, journals and radii are hardened. This procedure involves phase transitions in the material, close to the surface, resulting in a martensite layer (hardened region) and a transition zone to the unhardened material at the core.
The hardening leads to an increase in hardness as well as compressive stresses at the hardened region, both of which results in an increased local fatigue strength. In the industry the induction process and subsequent quenching is in large based on experience and it has in general not been extensively simulated. It is of interest to correlate simulations with measurements to gain knowledge as well as estimating the properties of the hardened region for use in fatigue models.
The induction hardening is a multi-physics problem including electromagnetics, thermo-dynamics, structural mechanics and austenite decomposition (phase transitions). These can be simulated jointly using FEA software Comsol Multiphysics.


Your profile:
Knowledge in Finite Element Method / PDE is required and some knowledge related to structural mechanics, thermo-dynamics and metal phase transitions is preferred.
Knowledge in some scripting language, preferably Python and some object oriented language. Experience using Linux/bash is a plus.
Interest in solving problems and creating virtual models to mimic reality

The thesis project is intended for 2 students
The Master of Science Thesis work will be performed at Volvo Group Trucks Technology, (Gothenburg, Sweden)


Industry supervisors: Staffan Häglund (supervisor) and Martin Svensson (manager) Volvo GTT
University supervisors: TBD
Starting date: January 2024


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