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　BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given here below, the appended claims, and the accompanying drawings in which:

FIG. 1 is a flow diagram illustrating the method of the invention.

FIG. 2 is a side view of an article of the present invention in the form of a differential housing.

FIG. 3 is a top view of the differential housing of FIG. 2.

FIG. 4 is a side view of an article of the present invention in the form of a second differential housing.

FIG. 5 is a top view of the differential housing of FIG. 4.

FIG. 6 is a top view of an induction coil of the present invention.

FIG. 7 is a side view of the induction coil of FIG. 6.

FIG. 8 is a top schematic view illustrating a differential housing placed within an induction coil according to the method of the invention.

FIG. 9 is a cross-sectional view of section 9—9 of FIG. 8.

FIG. 10 is a top schematic view illustrating a second differential housing placed within an induction coil according to the method of the invention.

FIG. 11 is a cross-sectional view of section 11—11 of FIG. 10.

FIG. 12 is a cross-sectional view of section 12—12 of the differential housing of FIG. 3 that has been induction hardened by the method of the invention.

FIG. 13 is a cross-sectional view of section 13—13 of the second differential housing of FIG. 5 that has been induction hardened by the method of the invention.
　
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-13, the present invention comprises a method 1 of induction heat treatment. Method 1 comprises the steps of: selecting 10 an article 100 for heat treatment, such as differential housing 200, comprising a metal wall 205 having an upper hub portion 210, a lower hub portion 215, a bell-shaped portion 220 that is located between the upper hub portion and the lower hub portion and a longitudinal axis 225 extending through each of the upper hub portion 210, lower hub portion 215 and bell-shaped portion 220, the bell-shaped portion 220 having a bell-shaped outer surface 230, an inner surface 235 and a plurality of windows 240 extending from the outer surface to the inner surface; selecting 20 an induction coil 300 comprising a hollow metal channel 305 having a first termination portion 310, a second termination portion 315 and a semi-rectangular inductor portion 320 that is operably connected to the first termination portion 310 and the second termination portion 315; wherein the induction coil 300 is adapted to receive the article 100, such as differential housing 200, and apply a plurality of magnetic fields to a heat treatment portion 245 thereof; placing 30 the article 100 within the inductor portion of the induction coil 300; rotating 40 the article 100 within the induction coil 300 at a selected speed; energizing 50 the induction coil 300 to apply the magnetic fields and produce induction currents within the heat treatment portion 245 of the article 100 for a time sufficient to induce heating of the heat treatment portion 245 to a heat treatment temperature (TH) to at least a selected case 250 depth; and cooling 60 the heat treatment portion 245 of the article 100 to a temperature (TC) to the selected case 250 depth. The method 1 of heat treatment, article 100, differential housing 200 and induction coil 300 are described more particularly below.

With regard to the step of selecting 10 an article 100, this method of induction heat treatment is ideally suited for the induction heat treatment of articles having a curved outer surface, such as differential housing 200, as shown in FIGS. 2-4. Preferably, article 100, such as differential housing 200, comprises a metal wall 205 having an upper hub portion 210, a lower hub portion 215, a bell-shaped portion 220 that is located between upper hub portion 210 and lower hub portion 215 and longitudinal axis 225 extending through each of upper hub portion 210, lower hub portion 215 and bell-shaped portion 220. Bell-shaped portion 220 has a bell-shaped outer surface 230, and inner surface 235 comprising a generally spherical upper portion 260 and a generally cylindrical lower portion 265 and a plurality of windows 240. Metal wall 205 preferably comprises cast nodular iron, such as may be defined by specifications or standards such as ASTM A536-84, ASTM A395-80, ASTM A476-82, A476-84, ASME SA395, ASME SA476, SAE J434c and Mil-1-24137. Metal wall 205 is typically formed by casting using well-known casting methods, such as sand casting, such that upper hub portion 210, lower hub portion 215, and bell-shaped portion 220 are all formed simultaneously as a single wall. As-cast nodular iron has a characteristic microstructure comprising a matrix that is a mixture of varying proportions of ferrite and pearlite with nodules of graphite distributed therein. Preferably, the graphite nodules are spheroidal. As the amount of pearlite increases, the strength and hardness of the iron also increases. The differential housings 200 shown in FIGS. 2 and 4 have somewhat different designs, but share many of the same features. As such, they have been numbered using the same reference numerals to illustrate the common features and to illustrate how the present invention may be applied to articles 100, such as differential housings 200, that are of somewhat different design.

Referring to FIGS. 2 and 4, empirical evidence as well as structural analysis suggests when a torque load is applied to differential housing 200, that the region of highest stress, and thus the highest likelihood of fracture as the torque load on differential housings 200 is increased, lies within the shoulder of the housing 200 adjacent to the top of windows 240, represented in FIGS. 2 and 4 as the region between lines A—A and B—B. Therefore, in order to achieve higher torque load capacity in a housing of a given size, it is desirable to strengthen and toughen this region by induction heat treatment. This region may be referred to as heat treatment portion 245. It is preferred that the microstructure within heat treatment portion 245 comprise a matrix that is substantially tempered martensite, with spheroidal nodules of graphite distributed therein. By substantially tempered martensite, it is meant that the matrix may contain some softer microstructural products, such as ferrite and pearlite, but that the largest weight fraction of the matrix should be tempered martensite, and preferably substantially all of the matrix should comprise tempered martensite. It is also preferred that the induction heat treatment avoid any substantial solutionizing of the graphite nodules in heat treatment portion 245, as it is known that any substantial solutionizing of the graphite nodules will reduce the strength and toughness of the associated portion of the microstructure.

Referring to FIG. 1, having selected 10 article 100, such as differential housing 200, method 1 comprises the additional step of selecting 20 an induction coil 300. Referring to FIGS. 6 and 7, induction coil 300 comprises a hollow metal channel 305 having a first termination portion 310, a second termination portion 315, and a semi-rectangular inductor portion 320 that is operably connected to the first termination portion 310 and the second termination portion 315. The semi-rectangular inductor portion 320 comprises a semi-rectangular lower coil portion 325 comprising a first L-shaped section 330 having a first termination end 335, that is connected to the first termination portion 310, and a first lower lateral end 340, and an opposed second L-shaped section 345 having a second termination end 350, that is connected to the second termination portion 315, and a second lower lateral end 353; a semi-rectangular upper coil portion 355 having a first upper lateral end 360 and a second upper lateral end 365, and that is located above and is proportionately smaller than the lower coil portion 325; a first lateral portion 370 that connects the first lateral end 360 of the upper coil portion 355 to the first lateral end 340 of the lower coil portion 325, and a second lateral portion 375 that connects the second lateral end 365 of the upper coil portion 355 to the second lateral end 353 of the lower coil portion 325. The heating of article 100 is primarily provided by magnetic fields produced by first lateral portion 370 and second lateral portion 375, and the respective ends of upper coil portion and lower coil portion when induction coil 300 is energized. Both upper coil portion 355 and lower coil portion 325 must be sized so as to receive article 100, such as differential housing 200, without interference while maintaining close proximity to permit coupling of the magnetic fields produced by first lateral portion 370, second lateral portion 375 and the respective ends of upper coil portion 355 and lower coil portion 325 to the surface of article 100. In the case of differential housing 200, the spacing was about 13 cm. The spacing of upper coil portion 355 and lower coil portion 325, and the respective lengths of first lateral portion 370 and second lateral portion 375 must be adapted depending on the design of differential housing 200 and the desired length or size of heat treatment portion 245.

As shown in FIGS. 6 and 7, first termination portion 310 and second termination portion 315 are adapted to connect inductive coil 300 to a power supply (not shown). While the arrangement of elements is provided to illustrate an embodiment of induction coil 300, the coil is not limited to the particular embodiment shown. For example, first termination portion 310 and second termination portion 315 could possibly also be incorporated into upper coil portion 355 rather than lower coil portion 325, with a corresponding rearrangement of the other elements of induction coil 300. Referring again to FIGS. 6 and 7, induction coil 300 may comprise any suitable size, cross-sectional shape and composition, depending on the exact nature of article 100 that is to be used therewith. However, in the case of differential housing 200, the spacing of the first and second upper lateral ends 360 and 365 of upper coil portion 355 was about 13 cm and comprised a hollow, rectangular, 99% copper tube 116 having an external width of 10 mm and an external height of 10 mm, and sidewall thickness of 1.1 mm. Induction coil 300 must be adapted so as to receive article 100, while preferably maintaining as close a spacing as is practicable, so as to maximize the inductive coupling with article 100 when induction coil 300 is energized, and yet not interfere with the rotation of article 100, as discussed herein. Induction coil 300 is preferably adapted so that longitudinal axis 225 of article 100 may be easily aligned to be parallel to and coincident with longitudinal axis 385. Induction coil 300 also preferably comprises quench blocks 380 as shown in phantom in FIGS. 6 and 7. Quench blocks 380 are connected to known means for providing a quenchant, such as a storage tank or supply line, and includes a plurality of openings through which quenchant may be sprayed onto article 100, as described below.

Referring to FIGS. 1 and 8-11, the next step of method 1 comprises placing 30 the heat treatment portion 245 of article 100, such as differential housing 200, within the induction coil 300. Placing 30 comprises providing a rotatable means for placing and rotating article 100 and performing the subsequent steps of method 1. As discussed above and illustrated in FIGS. 8-11 with regard to differential housing 200, housing 200 is preferably placed within induction coil 300 so that its longitudinal axis 225 is parallel to and coincident with longitudinal axis 385 of induction coil 300. Heat treatment portion 245 is placed adjacent to induction coil 300, such that the magnetic field produced when induction coil 300 is energized is inductively coupled to heat treatment portion 245. Differential housing 200 may be placed into induction coil 300 by any number of suitable known means for holding and rotating differential housing 200, such as a rotatable jig or fixture. It is also preferable that means for holding and rotating differential housing 200 be selected so as to minimize any interference with the magnetic fields generated by induction coil 300.

Referring to FIG. 1, the next step of method 1 comprises rotating 40 differential housing 200 within induction coil 300 at a selected speed. This speed may be any suitable speed and may comprise a variable speed during or within the subsequent steps of method 1. Rotation is used to compensate for the fact that induction coil 300 has a region where first termination portion 310 and second termination portion 315 join semi-rectangular inductor portion 320 where the resultant magnetic field is non-uniform and generally reduced as compared to adjacent sections of induction coil 300. In the case of the application of method 1 to differential housing 200 as described herein, the rotational speed was between 20 to 100 rpm.

Referring to FIG. 1, the next step of method 1 comprises energizing 50 the induction coil 300 to a selected energy level to apply the magnetic field and produce an induction current within heat treatment portion 245. In the case of nodular iron, such as SAE D-5506, to provide induction hardening, this energizing 50 must be performed for a time sufficient to induce heating of heat treatment portion 245 to a heat treatment temperature (TH) to at least a selected case 250 depth, such as the required or desired hardened case 250 depth. For differential housing 200, it is preferred that the case 250 extend through the entire thickness of metal wall 205 within heat treatment portion 245. For differential housing 200, and induction coil 300, the step of energizing 50 comprised applying power from a commercially available power supply of a type used for induction heat treatment in a range of about 1.0 kHz, and for about 6-12 seconds. In the case of differential housing 200, this step of energizing 50 was sufficient to heat the entire thickness of heat treatment portion 245 to a temperature that was above the austenite transition temperature. The austenite transition temperature for the nodular iron compositions noted herein is about 1600-1900° F. It will be readily understood that the inductive frequency and power can be altered depending on the size, shape, composition and other factors associated with differential housing 200, the specific design of inductor coil 300, as well as other factors.

The next step of method 1 comprises cooling 60 heat treatment portion 245 of article 100. Cooling 60 comprised quenching heat treatment portion 245 in an aqueous quenchant comprising 3-5% Aqua Quench 251 for a time sufficient to heat treatment portion 245 to approximately 150-100° F. below TC. Quenching was accomplished by pumping a large volume of the quenchant through a plurality of holes in quench block 380 onto heat treatment portion 245. In the case of differential housing 200, the quench time was about 10-15 seconds. The quenchant flow rate was about 15-25 gpm.

Referring to FIGS. 12 and 13, following the step of cooling 60, the hardness of differential housing 200 on the surface of heat treatment portion 245 was about RC 40-50, with a hardened case 250 that extended through the thickness of metal wall 205. The microstructure comprised a martensite matrix with generally spheroidal nodules of graphite located therein. No significant solutionizing of the graphite nodules was observed.

The foregoing discussion discloses and describes an exemplary embodiment of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.

qinsdau

BRIEF DESCRIPTION OF THE DRAWINGS
图纸简述
The present invention will become more fully understood from the detailed description given here below, the appended claims, and the accompanying drawings in which:
下面给出的讲解、附图能让我们更完全的清楚了解当前新发明。
FIG. 1 is a flow diagram illustrating the method of the invention.
图一是用流程图的方式来解释说明发明的方法。
FIG. 2 is a side view of an article of the present invention in the form of a differential housing.
图二是一差速机箱新发明的侧视图。
FIG. 3 is a top view of the differential housing of FIG. 2.
图三是图二中差速机箱的顶（俯）视图。
FIG. 4 is a side view of an article of the present invention in the form of a second differential housing.
图四为第二种差速机箱新发明的侧视图。
FIG. 5 is a top view of the differential housing of FIG. 4.
图五为图四的顶视图。
FIG. 6 is a top view of an induction coil of the present invention.
图六为一新发明感应器的顶视图。
FIG. 7 is a side view of the induction coil of FIG. 6.
图七为图六的侧视图。
FIG. 8 is a top schematic view illustrating a differential housing placed within an induction coil according to the method of the invention.
图八为差速机箱按照新发明装于感应器的俯视图解。
FIG. 9 is a cross-sectional view of section 9—9 of FIG. 8.
图九为图八中9-9截面视图。
FIG. 10 is a top schematic view illustrating a second differential housing placed within an induction coil according to the method of the invention.
图十为第二种差速机箱装于感应器的俯视图解。
FIG. 11 is a cross-sectional view of section 11—11 of FIG. 10.
图十一位图十11-11截面视图。
FIG. 12 is a cross-sectional view of section 12—12 of the differential housing of FIG. 3 that has been induction hardened by the method of the invention.
图十二为图3中按照新发明感应淬火后的差速机箱12-12截面视图。
FIG. 13 is a cross-sectional view of section 13—13 of the second differential housing of FIG. 5 that has been induction hardened by the method of the invention.
图十三为图5中按照新发明感应淬火后的第二种差速机箱13-13截面视图。
翻译的不好，见笑了！

qinsdau

The foregoing discussion discloses and describes an exemplary embodiment of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.
上述内容揭示并描述了新发明的一个实施示例，依照下面说明，本领域技术人员在不违背新发明的设计精神及合理范围的情况下根据这些讨论、图纸和说明可以做出各种更改、修正或变更。

nlj

On Qinsdau





图纸简述
The present invention will become more fully understood from the detailed description given here below, the appended claims, and the accompanying drawings in which:
下面给出的讲解、附加的说明，以及附图能让我们更完全的清楚了解当前新发明。在这些附图中：
FIG. 1 is a flow diagram illustrating the method of the invention.
图一是用流程图的方式来解释说明发明的方法。图一是一个说明发明所用的方法的流程图
FIG. 2 is a side view of an article of the present invention in the form of a differential housing.
图二是一差速机箱新发明的侧视图。图二是用一个差速机箱的形式来表现的本发明中一个零件的侧视图
FIG. 3 is a top view of the differential housing of FIG. 2.
图三是图二中差速机箱的顶（俯）视图。

FIG. 4 is a side view of an article of the present invention in the form of a second differential housing.
图四为第二种差速机箱新发明的侧视图。。图四是用一个二级差速机箱的形式来表现的本发明中一个零件的侧视图
FIG. 5 is a top view of the differential housing of FIG. 4.
图五为图四的顶视图。
FIG. 6 is a top view of an induction coil of the present invention.
图六为本发明的一个感应线圈的侧视图。
FIG. 7 is a side view of the induction coil of FIG. 6.
图七为图六的感应线圈侧视图。
FIG. 8 is a top schematic view illustrating a differential housing placed within an induction coil according to the method of the invention.
图八是按本发明的方法把差速机箱置于一个感应线圈中的俯视示意图。
FIG. 9 is a cross-sectional view of section 9—9 of FIG. 8.
图九为图八中截面9-9的剖面视图。
FIG. 10 is a top schematic view illustrating a second differential housing placed within an induction coil according to the method of the invention.
图十是按本发明的方法把一个二级差速机箱置于一个感应线圈中的俯视示意图。
FIG. 11 is a cross-sectional view of section 11—11 of FIG. 10.
图十一是图十中截面11-11的剖面视图。
FIG. 12 is a cross-sectional view of section 12—12 of the differential housing of FIG. 3 that has been induction hardened by the method of the invention.
图十二为图3中按照新发明感应淬火后的差速机箱12-12截面视图。图十二为按本发明的方法感应硬化了的图三中的差速机箱截面12-12的剖面视图
FIG. 13 is a cross-sectional view of section 13—13 of the second differential housing of FIG. 5 that has been induction hardened by the method of the invention.
图十三为图5中按照新发明感应淬火后的第二种差速机箱13-13截面视图。。图十三为按本发明的方法感应硬化<感应淬火吧？虽然意思相通，不过都这样叫吧——qinsdau>了的图五中的二级差速机箱截面13-13的剖面视图

班门弄斧，见笑，见笑。

[ 本帖最后由 qinsdau 于 2008-5-21 00:32 编辑 ]

nlj

建议版主采用沪江论坛上那种方式在可以在已经翻译上的网友的大作的基础上修改的方式，来减少重复劳动。

qinsdau

楼上说的很好，我只是没想到，求助帖是从别的论坛摘来的。
翻译的也不错，尤其是我的‘新发明’，您是‘本发明’，还是您的对或者更好。谢谢！
其余的是我语序安排上的不足，在此表示感谢！
只是有一点不敢苟同， induction coil翻译成感应线圈不大妥当吧。根据文意本‘ induction coil’为本发明或其一部分，但是感应线圈作为产品或者新发明都不大可能，所以应该是本发明的一个组件，所以我认为翻译成‘感应器’好一些。例如：FIG. 8 is a top schematic view illustrating a differential housing placed within an induction coil according to the method of the invention.
图八是按本发明的方法把差速机箱置于一个感应线圈中的俯视示意图。
从这里可以猜得放入‘induction coil’的目的是利用感应线圈感应加热从而进行热处理（个人猜测），但是如果说把工件放入感应线圈从中文来讲就不大通顺了，所以说感应器比较合适。比如中频感应热处理设备中感应加热部分就叫‘感应器’，而感应线圈只属于其一部分。
                                                    仅为讨论，不存在任何其它意思。

[ 本帖最后由 qinsdau 于 2008-5-21 00:28 编辑 ]

nlj

原帖由 qinsdau 于 2008-5-21 00:23 发表

                               
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楼上说的很好，我只是没想到，求助帖是从别的论坛摘来的。
翻译的也不错，尤其是我的‘新发明’，您是‘本发明’，还是您的对或者更好。谢谢！
其余的是我语序安排上的不足，在此表示感谢！
只是有一点不敢苟同， induction coil翻译成 ...

版主说得很有道理，尤其‘感应淬火’那个。我查了一下词典，induction coil 确实感应器和感应线圈的意思，induction hardening也确实是感应硬化和感应淬火的意思。该用哪个，有专业知识的人自行鉴别吧，呵呵。