The traditional methods of heating metals from old furnaces required considerable energy, fuel, time, and capital. The development of electric induction furnaces has enabled us to optimize the metal smelting and melting process and get the maximum output.
Understanding Induction Heating
Induction heating has become a well-known and commonly used process for industries worldwide to melt, bond, soften or harden metals. The difference between traditional and induction heating is that induction heating induces heat instead of torching or applying flames.
It works on the principle of electric currents. When an alternating current is applied, it creates an electromagnetic field, inducing an eddy current in the workpiece. These eddy currents flow against the electrical resistivity of metal. It generates localized and precise heat without direct contact between the inductor and the part.
A Quick Intro To Induction Forging
Forging is an old metal shaping and fabrication technique. Modern forging techniques include electric, hydraulic, or compressed air-powered hammering and using forging presses.
Induction forging is a type in which an induction heater pre-heats specific parts of metal and deforms them with the help of a hammer or press. The outdated methods of heating metal consumed a lot of time and resources. With induction forging, metals are quickly heated and are ready to deform.
An induction heater has a coil carrying alternating current, which rapidly changes the magnetic field and induces currents in the metal inside the coil. The coil current should be large enough to raise the temperature of the metal to the point where it becomes malleable for forging.
How Is Induction Heating Used For Forging?
The application for induction forging is diverse. Before you start assessing your applications, it would be best to have a good idea of how forging is done. Here’s what you need to know:
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Power Consumption
Since we have already discussed how induction heating works, we need to understand how much power is required for induction forging. The power supply can vary greatly. You may need some kilowatts to many megawatts. It depends on your forging needs and how much temperature is required to reach the curie or forging temperatures. The component geometry can also affect the power supply frequency from 50Hz to 200Hz. However, the average range for induction forging is between 1 kHz to 100 kHz.
You have to select a suitable power supply for your induction forging applications. Calculate the thermal energy required to raise the temperature of the chosen material. It will also vary with the metal type. For example, you will need a different power for Iron and steel.
To measure the required energy, you must include other factors and components like coil losses, radiated losses, and other system losses. Or you can ask for the professional help from induction experts like Electroheat Induction.
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Power Source And Output Frequency
The output frequency of the power source is a crucial parameter in induction forging. The heat is generated on the surface of the component. Choosing a frequency with a suitable penetration depth into the metal would be best. Heat can take time to penetrate the center of metal. Hot forming temperatures of metals are different.
In forging, we heat the metal to a point where we can change the shape. Too much heat or power can melt the surface while the core is solid. It can damage the metal and forging process.
The Benefits OF Using Induction Heating For Forging
Industries can optimize their forging process and increase their production. Following are the common benefits of doing that:
- The induction process is highly calculated and controllable. Other heating systems like gas furnaces require shutdown and pre-heat. There was not much flexibility and control.
- You have absolute control over the heat supply and production. In induction, forging heat is available on demand. Furthermore, the rapid availability of heat allows you to speed up your operations, and you can turn the power quickly in case of production errors and save productivity.
- The transfer of heat is much more efficient than other methods. It is also an energy-efficient process. The heat is produced with the help of electric current and coils, not from burning fuel and other materials.
- Induction forging protects the environment. The process is controllable and compact since there is no burning of elements, and very little waste and pollutants are produced. Moreover, there is no smoke or toxins in this process.
Electroheat Induction Can Help With Induction Forging
Electroheat Induction is committed to providing state-of-the-art heating and forging solutions to industries in South America, Europe, and the Middle East.
In addition to these regions, our partners in Mexico, South Africa, Canada, and the United States can also benefit from our products and services. Get our induction furnaces and other heating solutions with installation supervision, and support from our engineering team. Visit our website today to email us, or call +1-908-494-0726 to get a quote.
