Home

Optimization of Forging Induction Heater

Application: Forging

Software: ELTA 6.0/5.5

Type: Practical experience

Real story: Forging Company has an induction heater

for continuous heating of steel bar Dia. 40 mm.

 

p101

 

 

•    Heater has two connected in parallel coils. Coils have length of 1200 mm with 96 turns in each coil made of rectangular tubing A × T × t = 8 × 12 × 1.5 mm (A and T – axial and radial dimensions, t – wall thickness). Coil ID = 86 mm, refractory cylinder ID = 60 mm. Material – ceramics.
•    Coil voltage is app. 800 V at 1000 Hz.
•    Coils have 12 branches for water cooling each; total water flow rate is around 300 lt/min.

ELTA 5.5 (6.0) was used to find a possibility to improve the heater(more)

 

 

 

 

ELTA 5.5 (6.0) was used to find a possibility to improve the heater.

Comparison of simulation and experiment for copper billet heating

Application: Heat Treatment

Software: ELTA 6.0/5.5

Type: Practical experience

Industrial experiment:
Coil: ID = 31 cm, length 125 cm, turn number 91, tube width 1.2 cm, thermal insulation 2 cm, ceramic fiber.
Billet: Dia.= 24.2 cm, material – copper M2, initial temperature 25 °C, final – 850 °C.
Operating conditions: frequency 50 Hz, coil voltage 390 V, heating time 1100 sec (more).

 

 

 

 

 

 

 

ELTA 5.5 (6.0) was used to find a possibility to improve the heater.

Batch heating of tube

Application: General

Software: ELTA 6.0/5.5

Type: Investigation

Magnetic permeability is the most complicated physical property for simulation. In general, it is necessary to describe dependence of relative permeability upon temperature T and magnetic field strength H for each magnetic material. Accurate account for magnetic permeability is difficult due to three factors: magnetic hysteresis, non-linear dependence of Mu vs. field strength H and strong dependence of Mu from temperature when it approaches to Curie point. (more)

 p102

 

 

 

 

 

ELTA 5.5 (6.0) was used to find a possibility to improve the heater.

Induction Hardening of mill rolls

Application: Hardening

Software: ELTA 6.0/5.5

Type: Practical experience

Hardening of mill roles is one of very important induction technologies. There are several technologies of induction treatment of rolls: preheating, stress relieving, surface hardening and tempering. One of the technologies includes roll hardening using two inductors.
It is very important to predict the results of design especially for big rolls, which can weigh more than 20 tons and cost more than 50,000 Euros each. (more)

 p104

 

 

 

 

 

ELTA 5.5 (6.0) was used to find a possibility to improve the heater.