Abstract

Company FREAL-Ltd, St. Petersburg, produces a wide range of induction installations and power supplies and uses in it’s practice ELTA 6.0 and 2DELTA for design installations for forging, heat treating hard-facing and other technologies. To prove the efficiency and accuracy of the above mentioned software a lot of calculations and analysis of electromagnetic and thermal processes was carried out. One of them is the specially designed coils with non-uniform distribution of turns. Simulation allows improving the design of inductors, and obtaining optimal power value, heating time and frequency of HF power supplies. It is worth to mention that the programs are very useful for matching coils and generators with different layout of the power supplying circuits. Presentation is illustrated by description of some induction installations designed and produced by FREAL-Ltd using ELTA and 2DELTA. (Full text)

Abstract

This work aims to present simulation techniques for validation and revalidation of induction heating forging lines with approach on the thermal process and focuses on energy optimization through the use of the software 2DELTA-ELectroThermal Analysis.
Presentation contains information of induction heating of steel products, material characteristics, electromagnetic and thermal process in inductors, and simulation technique for optimal design of induction heating lines. 2DELTA is also an effective tool for learning induction heating.
2DELTA software allows users to systematically implement simulations for the induction heating applications for the most commonly geometries used in the forging shops. It is used by manufacturers and users of induction heating systems for thermal and electrical design of the induction heating forging line.
General considerations about use of simulation for validation and optimal design of heating lines are supported with an example of validation of one multi-stage line for heating billets for forging purposes. (Full text)

Abstract

Long induction heating lines are widely used in metallurgical, forging and tube industries. Big length and large number of inductors in one line, make optimal design of these systems rather complicated especially when the heating inductors are connected in series and parallel groups supplied from different power sources. Typically solid or tubular products with square or round cross-sections are being heated in lines. In some installations individual inductors or groups of inductors are supplied from the sources with different frequencies.
This presentation is devoted to design of such systems using program ELTA 6.0. ELTA is a program based on 1D Finite Difference Method (FDM) with semi-analytical account for the lengths of individual inductors and loads. Version 6.0 has an important 2D option for heating of bodies with rectangular cross-sections in the longitudinal magnetic field. All FDM calculations are related to a certain cross-section of the load, which passes through the processing steps in function of time. This algorithm allows the user to simulate multi-step heating processes in one “shot” and is very convenient for simulation of the induction lines with any number of stages describing heating in individual inductors, cooling in the gaps between them and even heating or holding in a flame or electric furnace.
Description of the computer assisted design of induction lines is illustrated by several examples. Due to very fast simulation it is easy to optimize the process of heating, i.e. to find an optimal variation of frequency and specific power versus time and therefore along the heating line. (Full text)

Abstract

The paper describes experience of authors in teaching induction heating using subject-oriented programs ELTA and 2DELTA. A guide-book for research and practical exercises in the field of induction heating has been developed for graduate and postgraduate students, young specialists and engineers. A set of practical tasks in induction heating, based on computer modeling using the ELTA and 2DELTA programs, is included in a course book, prepared by the authors. Several examples for teaching, training or self-education are presented in this paper to demonstrate the basic electromagnetic and thermal phenomena of induction heating, such as skin, edge and end electromagnetic effects. Use of ELTA and 2DELTA programs for design of induction processes for heating billets in line and slabs in multi-stage heater is also included in the paper. (Full text)