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Induction heating is a form of non-contact heating for conductive materials, when alternating current flows in the induced coil, varying electromagnetic field is set up around the coil, circulating current(induced, current, eddy current) is generated in the workpiece(conductive material), heat is produced as the eddy current flows against the resitivity of the material.
Induction heating is a rapid ,clean, non-polluting heating form which can be used to heat metals or change the conductive material’s properties. The coil itself does not get hot and the heating effect is under controlled. The solid state transistor technology has made induction heating much easier,cost-effective heating for applications including soldering and induction brazing ,induction heat treating, induction melting,induction forging etc.<
Optimization of Induction Heating Process for Hot Forging
Improving the efficiency of the manufacturing induction heating process is one of the ways to resolve the ecological issues, cost-saving pressure, and new environmental legislations. This paper presents the study on the in-line induction heating process prior to induction hot forging of an automotive crankshaft in order to find the potential solutions for improving the energy efficiency. The heating strategy that divides the induction heating line into groups for flexible control and saving operating energy was introduced. Optimization of the operating parameters of the induction heating system, including voltages and frequencies, was done using design of experiment in conjunction with numerical simulation, approximation, and genetic algorithm optimization techniques. In addition, thermal insulation was proposed to reduce the heat losses. The research results show that the energy can be saved through process parameter optimization approximately 6%. Furthermore, if the insulating covers at the open spaces between adjacent heaters are used, roughly 4% of additional amount of the energy consumption can be reduced.