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Key Points of Induction Hardening for Ball Screw Surface

2025,07,04
Key Points of Induction Hardening for Ball Screw Surface

I. Critical Role of Quenching Process
1) Process Positioning:
Surface induction heating quenching is the core process in Hojama ball screw manufacturing, directly determining the product's internal quality, precision retention, and service life.
2) Technical Principle:
The ball screw surface is rapidly heated to the quenching temperature and then rapidly cooled, forming a surface hardened layer (thread surface) and a tough core structure (maintaining the original metallography). This achieves a performance matching of "high surface hardness and wear resistance (hardness ≥58HRC) + strong and tough core for impact resistance".

II. Prominent Issues in Existing Processes
1) Hardened Layer Defects:
Shallow hardened layer and uneven hardness gradient distribution.
Slice inspection commonly shows insufficient hardened layer depth (failing to meet the standard of "ball radius + 1mm").
2)Crack Risks:
Axial or network cracks easily occur after induction quenching, leading to scrapping during grinding or fatigue testing.
Overheating causes coarse martensite needles, and stress concentration triggers cracks.
3)Fatigue Failure:
Local soft spots in the raceway lead to contact fatigue pitting, loss of preload, and precision failure.
The main failure form is contact fatigue wear (accounting for over 70%).

III. Technical Requirements for Quality Control
1) Metallographic Structure Standards:
The surface structure of the Ball Screw Drive should be grade 3-7 tempered martensite (tempered martensite + a small amount of carbides + an extremely small amount of retained austenite).
Coarse martensite needles (overheated structure) are strictly prohibited.
2)Hardened Layer Specifications:
Effective hardened layer (single side) = ball radius + 1mm, with a minimum hardness of 58HRC.
The hardness gradient must be uniform to avoid steep drops, causing stress concentration.

IV. Urgency of Process Optimization
1) Target Requirements:
Reduce the crack rate and improve wear resistance and contact fatigue strength.
Ensure dimensional stability and avoid post-processing precision degradation.
2) Influencing Factors:
Heating temperature, cooling rate, and processing parameters (such as inductor gap and heating time) directly affect quenching quality.
The existing process frequently causes out-of-control hardened layers and hardness gradients due to inaccurate parameter control.

V. Failure Consequences and Improvement Directions
1) Typical Failure Scenarios:
Raceway cracks during grinding → scraping in fatigue life tests.
Raceway soft spots → pitting → loss of preload → precision failure.
2) Core Improvement Directions:
Improve raceway wear resistance by precisely controlling hardened layer depth, hardness, and gradient distribution.
Optimize heat treatment parameters to balance surface hardness and core toughness, extending the linear motion ball screw's service life.
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