The majority of commercial codes used for computer modeling of induction heating processes are all-purpose programs originally developed for modeling processes occurring in electrical machines, motors, circuit breakers, transformers, and magnetic recording systems, and later adapted to induction heating needs. Despite the capabilities of modern commercial software, many generalized programs have difficulty taking into consideration [...]
Certain numerical computational methods or software are preferred for each family of induction heating applications. There is not a single universal computational method that optimally fits all types of applications. In recent years, the finite element method (FEA) became the dominant numerical simulation tool for a variety of engineering applications. Though FEA is a very [...]
Induction heating is widely used to heat metals prior to hot forming including forging, upsetting, rolling, extrusion, and other methods. Billets are heated either in cut lengths or continuously and are forged in presses, hammers, or upsetters, or are extruded. Steel components by far represent the majority of hot-formed billets, although other materials including titanium, [...]
The choice of frequency is always a reasonable compromise in induction heating. Too low a frequency might result in undesirably large ?, which could lead to poor coil electrical efficiency. Too high a frequency could lead to long heating times that, in progressive induction heating, would require a longer heating line. Obviously, there is an [...]
The selection of forging temperatures for steels is based on carbon content, alloy composition and forging specifics, including the temperature range for optimum plasticity and the amount of reduction. Based on these considerations, optimum forging temperatures that result in the material’s lowest flow stress (lowest forging pressure) are selected. Click here to read more.
The selection of principal process parameters, such as power, frequency and coil length, is a function of the metal to be heated, the required temperature uniformity, billet size and other parameters. Depending on the application, power ratings from hundreds to thousands of kilowatts and frequencies from 60Hz to 10kHz are commonly used. Click here to [...]
There are many parameters to be considered in designing an induction billet/bar heating system to meet the needs of modern forge shops. Application experience and computer modeling capability are important tools in developing effective induction heating system and avoiding unpleasant surprises related to common incorrect assumptions. Some of those incorrect assumptions that affect the quality [...]
In progressive induction heating applications (for example, in-line inductors), it is easier to predict the expected temperature distribution and to obtain the required temperature profile in the bar compared to the case of the bar end heating application. This is because each part of the bar in the progressive induction heater experiences the same magnetic [...]
There are three basic induction approached to heat RCS billets: static, progressive and oscillating heating. The most popular of these is the progressive multi-stage horizontal heating system, in which billets are moved through a single or multi-coil horizontal induction heater. As a result, the billet is sequentially (progressively) heated at predetermined positions inside the induction [...]
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