CHAPTER ONE 1.0 INTRODUCTION Induction heating is a non-contact method of heating conductive objects by means of electromagnetic induction.

This method of heating is of great interest to materials and manufacturing industries as it is fast, precise, and controllable. Though an induction heating system may be more expensive, it is usually preferable to other types of processing methods such as open flame heating or chemical processes. In most cases it also is the most efficient and precise heating method in practice today. Induction heating is caused by high frequency oscillations of a magnetic field. The magnetic field is produced by a solenoid with an oscillating current passing through it. The most efficient type of oscillating signal is sinusoidal in nature, and therefore the driving current must also be sinusoidal. The system must also include an inductor (being the work coil) as a passive component of interest. For these reasons, resonant converters become the most practical implementation A source of high frequency electricity is used to drive a large alternating current through an induction coil. This induction heating coil is known as the work coil. See the picture opposite. The passage of current through this induction heating coil generates a very intense and rapidly changing magnetic field in the space within the work coil. The work piece to be heated is placed within this intense alternating magnetic field. Depending on the nature of the work piece material, a number of things happen. The alternating magnetic field induces a current flow in the conductive work piece. The arrangement of the work coil and the work piece can be thought of as an electrical transformer. The work coil is like the primary where electrical energy is fed in, and the work piece is like a single turn secondary that is short-circuited. This causes tremendous currents to flow through the work piece. These are known as eddy currents. In addition to this, the high frequency used in Induction Heating applications gives rise to a phenomenon called skin effect. This skin effect forces the alternating current to flow in a thin layer towards the surface of the work piece. The skin effect increases the effective resistance of the metal to the passage of the large current. Therefore it greatly increases the induction heating effect of the induction heater caused by the current induced in the work piece. Components are induction hardened so that they can improve in resistance to abrasion. Most mild steel shafts are used to transmit motion; hence they carry attachments such as bearings through adapter sleeves or press fitted, Pulleys through taper lock bushes with key or press fitted. The bearing or the taper lock bush keys sometimes fail and the shaft exposed to too much abrasion. Sometimes the design purpose of the shaft may require that it is to be exposed

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to abrasion. Such conditions require that the part of the shaft on which much abrasion is expected be hardened. There are a number of other methods by which a component can be heated such as use of naked flame; oven etc. where the component is directly in contact with heater but induction heating is mostly preferred because it offers the following advantages: Rapid heating, low scaling Less machining Fast cycle time Precise control of temperature Localized heating No decarburization No large scale grain.

Induction surface hardening is widely applied in transport, machine tool and metal industries, engaged in heat treatment of machining elements.

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1.1 METHODOLOGY The plan in accomplishing this project has been summarized in the work schedule shown below

WORK SCHEDULE (3RD APRIL TO 24 APRIL 2011) DAY ACTIVITY Problem Definition Development of specifications Development of concepts Evaluation & Selection of best Concept Calculations Layout and Detail Drawings Conclusion and Recommendati ons 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1

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1.1.1 Problem definition The induction hardening machines which are available on the market are too expensive which makes people to have no desire of buying them as a result they prefer to use other methods of heating which have various negative impact on the work quality, environment and the operators health

1.1.2 Information search Search for information pertaining to need for this project was done. This has been explained later in literature review

1.1.3 Specifications development Based on the information found, the specification for the induction heat hardening machine was developed. The parameters looked at comprised of performance, environment, target cost, size, materials, maintenance, manufacture, life span, safety, ergonomics, etc.

1.1.4 Concepts development Four concepts were developed based on their mechanisms and operation employed. This will be looked at in detail later in the same chapter 1.1.5 Concepts evaluation and selection of best concept The concepts were evaluated using a matrix table. The best concept was selected based on the results.

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1.2 LITERAURE REVIEW Some Malawian foundry companies such as Encor Malawi and Formex Bolt and Nut Companies were visited to appreciate the work heating processes that they use and to seek reasons why the use such methods. At both Formex and Encor it was discovered that they use ovens, these ovens employ the use of used oil and charcoal, no induction heating is done as they do not have the induction hardening machine and it seem in Malawi at the moment we dont have any company with such equipment. The main reason is because of the high cost of the induction hardening machines which are not locally found. The need to have abrasion resistant components makes the foundry organization in Malawi to use direct contact methods of heat treatment therefore compromising the quality of the products they make and hence putting the safety of the operators which use such equipment at risk, there is also reduced machine reliability for industries that use such components which forces some to seek same components from outside this country hence the likely shortage in foreign exchange. From the patents search done some Americans and Germans have developed and patented the designs for work holding for induction hardening. Patent US3738636 by Hasten Remscheid, Germany, June 12, 1973 and US6409163B1 by Max. E. Stewart, Plainfield, IN(US). The designs in these patents are good in that the work can be swiveled to any angle and the work is rotated while been induction heated however such design are too complex and hence expensive for a country like ours. Also such designs are only good for very large work, not for a 150mm length shaft. Thus the need for this project cannot be overemphasized. The resources in our Polytechnic library, the internet and the industrial visits I paid to some local companies have helped me to pave the right way for this project

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1.3 DESIGN SPECIFICATIONS These are factors or parameters essential for the design of the induction heat hardening machine. Specifications include limitations placed upon the design, the inputs and outputs quantities and characteristics. 1.3.1 Performance The inductor must be dimensionally stable, must not deform by either mechanical or electrical influences Should be operated with minimum effort. Should employ cheap and unskilled labor of either sex to operate. Should use electricity as the source of energy for induction heating Process should be done within a time period of not more than ten minutes 1.3.2 Environment Should operate both in indoor and outdoor conditions. Parts should not corrode when exposed to moist conditions The work holder must be able to operate at temperatures beyond 800 oC Should operate on in electrified environment because of use of the inductor 1.3.3 Target cost Should be affordable. Cost not to exceed K150,000 1.3.4 Size and weight To occupy not more than 1m3 To weigh not more than 50kg. Shape of conductor must correspond with its purpose, i.e. should accommodate the whole part of the end of shaft to be heated Where possible machine members should be easily disassembled and reassembled for easy transportation.

1.3.5 Materials Should be made of locally available materials. Choice of selection will be based on high temperature resistance, cheapness, corrosion resistance and strength. 1.3.6 Maintenance Service frequency should not be more than twice a year. Should be serviceable by the local non-technical personnel. Should provide easy access to serviceable parts.
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1.3.7 Manufacture Should be easy to manufacture. Should employ conventional machine tools such as lathe, pillar drilling machine and common hand tools. No special tooling required. Joining should be by bolting, pins, screws and welding. 1.3.8 Life span Eight to ten years on average.

1.3.9 Safety Should not exhibit sharp edges and should generally offer maximum safety to operators. Proper guarding for moving parts and parts exposed to very high temperatures should be provided. 1.3.10 Ergonomics Should be attractive in appearance. Should not have shiny and reflective surfaces. Easily operated by hand or foot.

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CHAPTER TWO

2.0 CONCEPTS GENERATION

In conceptualization, four designs were done using free hand sketching on A4 papers. This is to ensure that ideas selection can be easily made. 2.1 CONCEPT 1: HAND OPERATED INDUCTION HARDENING MACHINE 2.1.1 DESCRIPTION This machine is made up of bracket supporting the operating lever, the vertical shaft on which the spring is fitted through the bush, the lower end of the shaft is threaded internally on which the threaded arm is fitted, the work holding device which has a locking screw, the lever lock, the inductor coil, the quench bath and the machine casing. This machine is manually operated using one hand. The spring returns the vertical shaft to its initial position once the lever is realized. The inductor is mounted below the work holder on one side and the quench bath lies on the other side. The work holder arm can be rotated to reverse the work end required and the threaded arm can also be rotated to bring work underneath either the quench bath or the inductor The holder is positioned in a way that when 20mm of work is inserted into the inductor, work is held at its midpoint in the work holder. 2.1.2 OPERATION First the work is mounted with its mid-point coinciding with that of the holder and locked. Then the operating lever is partially lowered so that 20mm of end of work enters the inductor coil which is then switched on until work is adequately heated to austenitic temperature range. The lever is locked when 20mm of work end enters the inductor coil. Then the lever is released so that work clears from the inductor coil. The threaded arm is then rotated so that work is directly above the quench bath and the work is lowered into the quench bath. The swiveling handle is the rotated when lever is released so that work is turned upside down. Then the work is lowered into the inductor again. When the other end is heated then the threaded arm is rotated to feed the work into the quench bath again. Finally the lever is realized and the work is removed
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from the work holder and another work piece is set and the process is repeated until all work is done. 2.1.3 Advantages No need for skilled labour. Ease of maintenance. The machine does not involve a lot of rotating parts, hence does not require any particular attention in terms of maintenance. Ease of manufacture. Manufacturing of this device does not call for specialized machine tools and equipment. Cheap than the other concepts

2.1.4 Disadvantages Laborious. The slowest process than all the other concepts

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2.2 CONCEPT 2: YOKE-TYPE INDUCTION HARDENING MACHINE 2.2.1 DESCRIPTION The yoke-type induction hardening machine consists of the motor that transmits motion to the rotating disc through the v- belts. The disc is mounted on the shaft that rotates on the two pillow block bearings. The other end of the shaft carries a pulley which is larger in size than the pulley on the motor to reduce the disc rotating speed. Attached on the disc is a round pin which rotates together with the disc away from disc centre, thus the disc act as a cam. Constrained to move linearly with the disc is a yoke which carries the work holding device so that as the disc rotates the yoke and thus the work holding device moves up and down. The inductor is mounted on top of the work holder and the quench bath is placed underneath the work holder and thus the work. The work holder is designed so that it rotates 180 0 to turn the work upside down. 2.2.2 OPERATION First the work is mounted in the work holder so that 20mm is inserted into the inductor coil. The coil is then switched on until the temperature reaches the austenitic temperature range for steel. Then the motor is switched on so that it stops when the yoke has moved to the lowest downward position and thus the whole work length is quenched in the bath. Thereafter the motor is run so that it stops when the yoke is mid position to clear work from both quench bath and the inductor coil then the work holder is rotated through 1800 to turn the work upside down. The motor is then restarted until the yoke returns to its default position (so that work enters the inductor coil by 20mm). The work is heated, and quenched as before. The work is removed and another new work-piece mounted and the process is repeated. 2.2.3 Advantages Simple to operate as no specialized skill is needed. Improved operator safety Reduced work handling than the hand operated one. Reduced cycle time Can be easily assembled and disassembled

2.2.4 Disadvantages Costly to properly design the yoke Costly to buy motor, pulleys and bearings
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2.3 CONCEPT 3: THE HYDRAULICALLY OPERATED INDUCTION HARDENING MACHINE 2.3.1 DESCRIPTION The hydraulically operated induction hardening machine comprises of two hydraulic double acting cylinders, the inductor, the quench batch, the work holder and the machine casing. Each hydraulic cylinder is provided with its own actuation lever. The two hydraulic cylinders form a dual hydraulic circuit. Each hydraulic cylinder circuit is provided with a four way control valve. The horizontal cylinder is for feeding work into the inductor when actuated for a forward stroke, it also positions the work ready for quenching into the quench bath. The vertical cylinder is for feeding work into the quench bath when actuated in the forward stroke but also positions the work at the height of the inductor coil when actuated in the backward stroke. All the two hydraulic cylinders are held to the machine casing through pins by the brackets welded to the casing. The pins allow the cylinder to freely take some important positions which would not have been achieved if they were constrained to one plane. The inductor coil and the quench bath are positioned at their strategic points and does not move during operation For safety purposes the hydraulic circuit is provided with a relief valve in case pressure exceeds the rated one the relief valve releases the excess pressure. 2.3.2 OPERATION The hydraulically operated induction hardening machine is easy to operate. First the hydraulic pump motor is switched on, and then the work at its mid position is mounted in the work holder. Check that the work and inductor axises approximately coincide i.e. the vertical hydraulic cylinder takes its default position, actuate the horizontal cylinder in the forward position until work enters the inductor coil by 20mm as demanded. The inductor is now switched on until the required temperature is reached, then the horizontal hydraulic cylinder is actuated in the backward stroke so that the work is fed into the quench bath by the actuation of the vertical cylinder in forward stroke. When quenched the vertical cylinder is actuated in backward stroke to its default position. The work holder is then rotated 180 0 to feed the other end. The horizontal hydraulic cylinder feeds the work into the inductor coil. When heated to the appropriate temperature the work is quenched as before. Then the work is removed from the work holder ready for another work process. The sequence can be achieved in a short period of
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time, say, a minute. Position sensor can be installed to control the movements of the cylinders 2.3.3 ADVANTAGES It is faster than the screw type Ease of manufacture Comparatively short cycle time Easy to operate Improved operator safety

2.3.4 DISADVANTAGES Costly to buy motor, pump and hydraulic accessories

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2.4 CONCEPT 4: SCREW TYPE INDUCTION HARDENING MACHINE 2.4.1 DESCRIPTION The screw type induction hardening machine consists of the fixed threaded shaft (screw), the travelling nut which hold the work holding device (arm). The threaded shaft is held by the two pillow block bearings. The thread shaft is rotated by the motor through the v-belts. The motor speed is reduced by using a comparatively bigger diameter pulley at the driven side than the driver side. The work holder is designed in a way that it can be rotated 180 0 and has a locking screw. Underneath the work holder is a quench bath and directly above it is the inductor coil for heating the work. The work holding device moves up and down through the nut on which it is attached to. 2.4.2 OPERATION First the work is mounted on mid position on the work holder. Then the motor is switched on in the clockwise direction so that the nut and hence the work moves up into the inductor coil by about 20mm. The inductor is then switched on until the work is heated to the austenite range. Then the work is withdrawn from the inductor into the quench bath by running the motor in the anti-clockwise direction. Then the work holding device is brought to its default position by running motor in the clockwise direction and the work holder is rotated to turn work upside down so that process continues to heat and quench the other end of the work. When the cycle is finished the work is removed and another work is inserted and held in the work holder and another cycle begins. 2.4.3 ADVANTAGES Easy to operate Very short cycle time than all Reduced work handling Safe to use Portable

2.4.4 DISADVANTAGES Expensive

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CHAPTER THREE

3.0 CONCEPTS EVALUATION In order to come up with a viable and economical design of the heat hardening machine, four concepts were evaluated against the set parameters such as performance, size, safety, manufacture, product cost, portability, durability and ergonomics. CONCEPT EVALUATION MATRIX TABLE CONCEPT CRITERIA 1 Performance Size Safety Easy of manufacture Production cost Easy of maintenance Portability Durability Ergonomics Materials R E F E R E N C E 2 + + + + + + S 3 + + + + + S 4 + + + + + S 1 + + + S 2 R E F E R E N C E 3 S S S + + + S 4 S 1 + + + + S 2 + S S + S + S 3 R E F E R E N C E 4 + S 1 + + + + S 2 + + + + + + + + + S 3 4 + R + E + F - E + R + E + N + C + E S 1 2 3 4

Concept 1 Total + Total Total S 16 11 3

Concept 2 6 18 6

Concept 3 8 16 6

Concept 4 21 6 3

KEY + S = Better than = worse than = same as

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3.1 SELECTION OF BEST CONCEPT Selection of best concept was based on the results obtained from the evaluation matrix table. The outcome from our matrix table clearly indicates that concept number 4 is the best concept out of the four concepts which were developed. Concept number 4 has been selected because it has more positives than all the other concepts.

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CHAPTER FOUR 4.0 DETAILED DESIGN ANALYSIS OF THE SCREW TYPE INDUCTION HARDENING MACHINE 4.1 DETAILED DESCRIPTION OF THE CONCEPT The machine frame is made up of a structure of 25mm x 24mm x 5mm angle irons. 8mm plate provides the base for the motor and the bearings holding the rotating screw. The angle irons are welded to each other to make the machine frame. The screw shaft is stepped to provide bearing positions. Attached to the nut are the guide plate and the work holding device. Attached to the work holding arm is a work holder and round bar. The motor transmits rotary motion to the screw shaft through the v-belts and a pulley system. The rotary motion of the screw shaft transmits a linear motion of the nut which is constrained from rotation by the guide plate welded to it thus the work holding device is made to vertical up and down motion of the work. In the upward motion the work is feed into the inductor coil which is mounted directly on top of the work holder. The quench bath is located underneath the work holder so that work is fed into it during its downward movement. The details of each member has been explained and analysed separately as below.

4.2 DESIGN CALCULATIONS

a) Work details The given mild steel work dimensions are as follows: The ends of 20mm each are to be induction hardened Work area, A = = 78.54 x 10-6 m2 Diameter = 10mm Length = 150mm

Volume of work = area x length = 78.54 x 10-6 x 0.15 V = 11.781 x 10-6 m2 Mass of work, m = density x volume m = v for mild steel = 7.85 x 103 kg/m3
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therefore m = 7.85 x 103 kg/m3 x 11.781 x 10-6 m2 = 0.092 kg weight, p = 0.092 x 9.8 = 0.9016 N say, p =1N b) Work holder Cork which has a very low thermal conductivity of about 0.043 W/mk can be used as in insert in the mild steel bush of the work holder. Mild steel has a thermal conductivity of about 48.5 W/mk. Cork is used to surround the work piece to be heated so that there is minimal heat transfer to the other machine member. If a cork insert of 8mm thick is used, the mild steel bush would have an internal diameter of 10mm (work diameter) + 8mm (cork thickness) +0.5mm (clearance for insertion of work) = 18.5mm Therefore outside diameter of the bush = 30mm so that it has a thickness of about 5mm Bush length = 25mm The bush would be provided with an M6 tapped hole for locking the work in position. Bush area = (0.032 0.01852) = 438.1 x 10-6 m2

V = 438.1 x 10-6 x 0.025 = 10.9525 x 103 Mass of bush = 11 x 10-6 x 7.85 x 103 M = 0.08635 kg P = 0.08635 x 9.81 = 0.85N On to the work holding bush is welded a mild steel bar of 10mm diameter, 100mm long. At the other end of the steel bar is a work swiveling handle. Mass of steel bar = v = A = m = m
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7.85 x103 x = 0.062kg

load, p = 0.062 x 9.8 = 0.61N

80mm A R 2N Vector diagram

F B

Shear Force diagram 0.08Nm

-2N

0 Bending Moment diagram

F = Pwork + Pbush = 1 + 1 = 2N Neglecting the weight of the steel bar itself and resolving forces vertically R = F = 2N Maximum moment takes place when the shear force = 0, i.e. at

Hence Mmax = R x 0.04 = 2 x0.04 Mmax = 0.08Nm For steel shafting, the permissible shear stress, p = 55MN/m 2 for no key assuming the steel bar is made to be of diameter 10mm Area of bar = Shear force = 2N Therefore shear stress, = = 25464.8 N/m2 = 0.025 N/m2
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Which is very much low than the permissible shear stress. This can also allow the hand turning of work effect.

Shear out failure in the plate is p = P = R + Psteel bar = 2 + 0.61N P = 2.61N a = 20.5mm .. given t = 10mm Therefore p =

where t is the plate thickness

= 6365.9 N/m2

Which is well below the allowable shear stress for mild steel c) The plate welded to the nut and the holding device This plate is to both the nut and the plate that hold the work holder steel bar. If this plate is 10 x 20 x 200 mm, neglecting the mass of this plate M = 0.01 x 0.02 x 0.2 x 7.85 x 103 = 0.314 kg F 200mm A R Vector diagram B

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31.65N

Shear Force diagram 3.165Nm

-31.65N

0 Bending Moment diagram F = 2.16 + P 1st plate = 2.61 + 29.4N F = 31.65N Resolving forces gives R = F = 31.65N At maximum bending moment shear force = 0

Therefore maximum bending moment takes place at = Mmax = R x 0.1 = 31.65 x 0.1 = 3.165 N/m Shear stress in the plate is = = 15825 N/m2 This is well below the allowable stress of mild steel plates. d) Power screw analysis

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The power screw convert rotary motion of the drive motor into a linear (up and down) motion of the work through the nut. The screw can be lubricated with grease to reduce friction. The screw rotates and is held by the two pillow block bearings. The nut is prevented from turning but is able to slide up and down. The modified square thread form is chosen because unlike the square thread it can be cut using milling cutter, a die or a thread rolling. The modified square thread has faces inclined at an angle of 50 Suppose the work is to travel at 20mm/s Then the rubbing speed of the nut = 20mm/s = 0.02m/s But rubbing speed = V = r = 0.2m/s 1 Now if we select a 30mm diameter shaft for our screw then the recommended pitch is P = 8mm Thread depth t = 0.5p Therefore t = 0.5 x 8 = 4m Minor diameter, di = D P = 30 8 = 22 Pitch diameter, d = D t d = 30 4 = 26mm From equation 1 V = r = 0.02 m/s Therefore = But Therefore N = Say N = 15 rev/min Therefore V V = 20.42 mm/sec When the work is being raised to enter the inductor coil Torque is T = F tan ( + ) when lowering T = F where tan ( + ) is the coefficient of And for a modified square thread tan friction and for lubricated thread,
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rads/s

= 14.69 rev/min

0.02042 m/sec

can be approximated to be 0.125

 = 50 for a modified square thread Therefore tan = 7.1520 The helix angle, tan = = 5.594 F = 31.65N + P2nd plate +Pguide = 31.65 + 3.1 + Pguide Approximating the total load carried by the nut as 40N, we have the following Torque to raise load = 40 x tan (7.152 + 5.594) Traise = 0.11763 N/m Tlower = 40 x tan (7.152 5.594) = 0.0979 = 0.125477

= 0.01414 N/m Screw thread efficiency is = = 0.433 = 43.3% Since a rolling element bearing is used as a thrust collar, the friction is small and can be neglected.

The number of threads in the nut is given as n = Let the length of the nut be equal to 30mm then n = threads = 3.75 say n = 4

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The length of the thread taking the load is

And the bearing pressure

Pb

Pb = 30.6063 KN/m2 This is below the allowable bearing pressure for a rubbing speed of 0.02. From Mechanical Design Data Manual, February 1999 the allowable bearing pressure for a rubbing speed of less than 0.05m/s is 20 MPa. The bending stress in the thread is b y = , h = 0.5437p Therefore b = b = b = 77652.17 N/m average sheer stress in the thread is av = av = 28146.32N/m2 axial stress in the root is v = where dt = Therefore r = 88419.4 N/m2 = = = = = for a modified square thread but m = F and I = ,

Torsional shear stress at the root is st 56262.6475N/m2

Combined sheer stress in the root is s max = =

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s max = 104802.08 N/m2 from the Johnson formula, the critical force for buckling is F cr = At y (1 where at At = = 452.4 x 10-6 m2

for mild steel, appendix 1, Hearn vol.1 E = 207 GN/m2 y = 175 MN / m2 K = = 6mm For maximum slenderness ratio of 100, the maximum length of travel is 600mm But since our work will not be required to travel that much, the travel length can be set to be 300mm Therefor slenderness ratio = Hence Fcr = 452.4 x 175 x (1 Fcr = 74931.535 75 KN = = 50 )N

Using a design factor of say 5, the maximum safe load for buckling is 15KN Since the actual load is 40N, then the screw is safe in the buckling e) Selection of pulleys and belts

If a small unit geared drive (motor plus gear box) of 1.5KW, input speed of 720 rev/min and an output speed of 30rev/min is selected. The speed ratio between the drive unit and the driven (power screw) is = 2 Therefor the selected will have a speed ratio of 2 service factor for over 16 hours light duty machine = 1.3 Design power = 1.5 x service factor = 1.5 x 1.3 = 1.95, From Table 4 page 75 Designing V-belt drives by Fenner Power transmission gives an A-section belt. Also on Table 6 page 76 of the same, motor power of up to 3.0 KW indicates a minimum pulley diameter of 67mm.
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Thus the driver pulley will have a pitch diameter, d = 67mm Therefore the driven pulley will have a diameter, D = 67 x 2 = 134mm

Belt length L is L = 2c + 1.57 (D + d) + By letting C = 400mm we have L = 2 x 400 + 1.57 (134 + 67) + = 800 + 315.57 + 0.41875 L = 1116mm Looking from table on page 7 on precision built V-belt size the nearest belt size is C1170 which is 22 x 14 mm in section Hence 1170 = 2c + (1.57 (134 + 67) + 1170 = 2c + 315.57 + 854.43c = 2c2 + 16.75 2c2 854.43c + 16.75 = 0 Using quadratic equation we find C = 427.2mm. Thus the centre distance is supposed to be 427.2mm.

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CONCLUSION Malawi is a developing country which is trying to reduce number of imported products hence the coming of the design of a screw type induction hardening machine is a timely invention. Implementing this design would mean reliable locally made machine products since their structural strength will be precisely achieved through the screw type induction hardening machine. The screw type induction hardening machine design is made of locally available materials, for example the screw and most the parts are made of mild steel which is cheap and is easily welded than other metals. The motor, pulleys and v-belts can be locally purchased. The safety of the people working in our local foundry factories will be greatly improved and environmental degradation due to burning of used oil and charcoal in foundry industries will be greatly reduced if not eliminated. Any design aimed at improving the lives of people and the environment is of great importance in a civilized world like ours hence the need for conducting a project of this nature cannot be overemphasized Doing this project was challenging because of the short time period were given but it has been a success. As each project passes, new skills in designing are grasped especially the importance of good planning when carrying a project.

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RECOMMENDATION For better control of the induction heating I recommend that temperature sensors be incorporated in this design. Position sensors can also help in heating a precise length of the work at hand so that before any work is done the sensors would first be set and once the process of heating starts quality work is expected. I also recommend use of water soluble polymers or water salt mixture as quenchant since it displays better properties in quenching mild steel. The work holder and the inductor coil can be modified so that a wider range of work can be heated using the same machine. Since it was found that the forces from the work which was being studied were so small, bigger diameter work can be used in this machine but that should be done in consultation with myself as a designer. Finally I recommend that this design should be tried, for I expect great results.

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REFERENCES
Junaid A. Siddiqui and Ghulam Rasool Mughal (November 28, 2007), Major Factors in the Design of Induction Heating Equipment for Surface Hardening, College of Engineering P.G.Simpson, Induction heating, coil and system design., McGraw-Hill. Daisuke Suzuki, Koji Yatsushiro, Seiji Shimizu, Yoshio Sugita ,Motoki Saito and Katsuhiko Kubota, Development Of Induction Surface Hardening Process For Small Diameter Carbon Steel Specimens www.wikpedia.org (induction hardening of steel, 2002). Ostrrowsky O. (1981), Engineering Drawing for Technicians, Vol. 2, Edward Arnold Publishers Gombachika H. S. (PhD) (2005) Final Year Project Guide, University of Malawi-The Polytechnic,.

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