Multiphysics Analysis Process of Front-End Process for Induction Hardening of 3D Structures to Predict Structural Deformation

The torsion beam, integral to rear suspension systems in vehicles, is a critical component where strength and durability must be prioritized in specific regions. To enhance the strength of these regions, induction hardening, a localized heat treatment method, is employed. However, the application of this treatment introduces distortion, which compromises the precision of welding between components and raises significant concerns about product quality and safety. To address these challenges, the present study introduces a front-end analysis process for induction hardening aimed at predicting distortion following heat treatment. A three-dimensional model of the product was utilized to simulate the front-end process of induction hardening. A coupled analysis of electrical and thermal fields was conducted to replicate the heating effect induced by coils during the heat treatment process. Additionally, a thermo-structural coupled analysis was performed to predict the distortion occurring during the cooling phase. A comparative analysis with actual product measurements demonstrated that the proposed method achieved a distortion displacement prediction accuracy of 98%, thereby validating the efficacy of the proposed analysis process.