Induction forging is a process in which an induction heating system preheats metals and presses them into shape using a hammer or press. The applications for induction forging vary greatly, but before you get started assessing your applications, it's helpful to have a good understanding of the process. So, let's get started.
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Read our guide: Induction Heating for Forging
More Induction Forging Application Notes
Principal Process
First, it's important to understand that induction heating is a non-contact process that uses the main principles of electromagnetic induction in order to effectively produce heat. Electric current can flow through a material when it is placed in a strong alternative magnetic field; this causes Joule heating. With magnetic materials, the excess heat is generated below the Curie Point -- the Curie point is the temperature at which certain magnetic materials undergo a sharp change in their magnetic properties. The Curie point of iron, for example, is 1,418 degrees Fahrenheit (770 degrees Celsius).
The depth of the generated current is determined by both the frequency of the alternating field as well as the material's permeability. Materials with high permeability (100&#;500) are easier to heat via induction heating. Iron and its alloys respond well to induction heating due to their ferromagnetic nature.
Consumption of Power
Before getting started with your own applications for induction forging, you need to understand the power that it requires. The power supplies needed for induction forging can vary greatly, from just a few kilowatts to multiple megawatts. The component geometry can also dictate power supply frequency, which can vary from about 50 Hz to 200 kHz. Keep in mind that most applications for induction forging use a range of between 1 kHz and 100 kHz.
Selecting the correct power for your induction forging application requires you to calculate the thermal energy needed to raise the chosen material to the necessary temperature within the allotted time frame. After this measurement is determined, you'll have to factor in other components such as radiated losses, coil losses, and other system losses. (And, THE LAB at Ambrell can help you do this with complimentary applications testing.)
Output Frequency and Power Source
After determining the power consumption necessary for an induction forging application, you'll have to consider the next main parameter -- the output frequency of the power source. While the heat is primarily generated in the surface of the component, it's critical to choose a frequency that offers the deepest and most practical penetration depth into the work piece. You should also keep in mind that it does take time for the heat to penetrate toward the center of the work piece. Furthermore, if too much heat or power is applied too quickly, it is possible to melt the work piece's surface while the core is still cool.
Benefits
The top three benefits of induction forging are fast heating cycles, accurate heating patterns, and cores that remain relatively cold and stable. Induction forging, however, also boasts many benefits. First and foremost, the process is highly calculated, and therefore, controllable. Traditional heating systems, such as gas furnaces, require a preheat and shutdown, whereas induction forging applications do not. Furthermore, the heat is available on demand with rapid availability. If a downstream interruption to production ever occurs, the power can easily be turned off, preventing unnecessary energy loss.
Induction forging is also an energy-efficient process. This is a result of the heat being generated within the component as opposed to around it. The transfer of heat and energy is made much more efficient because the induction heating system only heats the work piece, not the atmosphere surrounding it.
Ultimately, understanding the processes and benefits of induction heating and forging applications is essential to determining what is induction forging and whether or not it's right for your process.
Additional Benefits
We've already discussed some benefits of the induction forging process; specifically, its controllable processes and energy efficiency. However, there are many more benefits that most people aren't quite aware of. For example, unlike other types of heating, induction forging does not create any harmful or toxic byproducts when the process is complete. It's a completely clean process that does not contribute to environmental waste. No smoke or toxins are created as a result of induction forging.
Furthermore, part of the answer to the question, "How does forging work?" includes the element of consistency with results. When all is said and done, the process is highly controllable, which means it can be easily and quickly repeated time-after-time with little-to-no change in the result. There's nothing unexpected or surprising about induction forging because there's no guesswork involved. Such uniform results help to prevent the need for post-forging machining.
Additionally, induction forging causes high temperature rises, ensuring that each component reaches its necessary temperature quickly and efficiently. This reduces the scale as well as the possibility for surface defects of the material upon completion.
Bar End Heating
Bar end heating is a type of forging in which only a portion of the bar is forged. These applications typically include hot heating of bolts and some mining tools. For example, the end of a bar might be heated and then hot heated to create a large fastener. Bar end heating is very similar to induction forging.
Ultimately, the efficiency of an induction heating system for a specific application depends on four factors: the characteristics of the part itself, the design of the coil, the capacity of the power supply, and the amount of temperature change required for the application. Understanding the detailed processes of induction forging is the best way to determine whether or not your business can benefit from forging with induction heating equipment.
What is induction heating? How does induction heating work? What materials does induction heating work best with? These are all common questions that people have about induction heating chillers.
In this blog post, we will answer all of those questions and more! We will also discuss the purpose of induction heating chillers, water vs. air chillers, and whether or not you need an induction heating chiller. Finally, we will introduce you to KKT Chillers and explain how our company can help you improve your induction heating process.
What is Induction Heating?
Induction heating is a process that uses electromagnetic induction to heat an electrically conductive object. The object is placed in a magnetic field and an alternating current is passed through it. This causes the object to heat up due to eddy currents, which are created by the changing magnetic field.
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Put simply, induction heating is a way to heat an object using electricity. This process has many applications, including cooking, welding, and heat treating. Induction heating can be used for many different purposes and across many different industries including:
- Automotive: induction heating is used for hardening and tempering gears, shafts, and other car parts.
- Food & Beverage: induction heating is used in food processing for cooking, pasteurizing, and sterilizing.
- Manufacturing: induction heating is used in welding and heat treating metals.
How Does Induction Heating Work?
Now that we know what induction heating is, let&#;s take a closer look at how it works. As we mentioned before, induction heating uses electromagnetic induction to heat an object. But how does this process work?
First, an alternating current is passed through a coil of wire (the primary coil). This creates a magnetic field around the coil. Then, the object to be heated (the secondary coil) is placed inside the magnetic field. The changing magnetic field induces an electric current in the object, which causes it to heat up.
The induction heating process is controlled by three main factors:
- The frequency of the alternating current
- The strength of the magnetic field
- The amount of time the object is exposed to the magnetic field
These three factors can be adjusted to control the induction heating process. For example, increasing the frequency will increase the rate at which the object heats up.
What Materials Does Induction Heating Work Best With?
Induction heating works best with materials that are good conductors of electricity, such as metals. This is because induction heating relies on induced currents to heat up an object. If the object is not a good conductor, the induced currents will be very weak and the induction heating process will be less efficient.
Some of the most common materials that are induction heated are:
- Steel
- Aluminum
- Copper
- Brass
Materials that should not be induction heated are:
The Purpose of Induction Heating Chillers
Induction heating chillers are used to cool induction coils during the induction heating process. This is necessary because induction coils can get very hot during operation and need to be cooled down to prevent damage.
There are two main types of induction heating chillers: water chillers and air chillers. Water chillers use water to cool the induction coils, while air chillers use air. Each type has its own advantages and disadvantages, which we will discuss in more detail below.
Water vs. Air Chillers
Water chillers are more effective than air chillers at cooling induction coils. This is because water has a higher specific heat capacity than air, which means it can absorb more heat per unit of mass. Water chillers are also less expensive to operate than air chillers. However, water chillers require a constant supply of water, which may not be available in all locations.
Air chillers are less effective than water chillers at cooling induction coils. However, they do not require a constant supply of water, making them more versatile. Air chillers are also easier to install and maintain than water chillers.
Do You Need an Induction Heating Chiller?
Not all induction heating applications require a chiller. For example, if you are only using induction heating for short periods of time, or if you are not concerned about the efficiency of the induction heating process, then a chiller may not be necessary.
However, if you are using induction heating for long periods of time, or if you need to maximize the efficiency of the induction heating process, then a chiller is recommended.
It is important to know, however, whether or not you need one. Some side-effects of not getting a heating chiller when your machine needs one could include:
- Your induction coil may overheat and be damaged
- The efficiency of your induction heating process may decrease
- Your induction heating machine may not work as well as it could
Pricing of Induction Heating Chillers
While pricing depends largely on the specific induction heating chiller you need for your application, and the company you are purchasing from, we have a few tips to help you get started:
- Air chillers are typically less expensive than water chillers.
- The size of the induction heating chiller will affect the price. larger induction heating chillers will be more expensive than smaller ones.
- Induction heating chillers can be bought new or used. Buying a used induction heating chiller may save you money, but it is important to make sure that the chiller is in good condition and suitable for your needs.
How KKT Chillers Can Help
At KKT Chillers we offer water-cooled induction heating chillers that are designed for use in industrial applications. KKT chillers use a closed-loop cooling system to cool the induction coils, which makes them more efficient than air chillers.
KKT Chillers are also easy to install and maintain, and they come with a variety of features that make them ideal for use in induction heating applications.
If you need an induction heating chiller, then KKT is the perfect choice. Contact us today to learn more about our products and how we can help you with your induction heating needs.
For more information, please visit Full Bridge Electromagnetic Induction Heater.
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