scholarly journals Numerical study of the induction heating of aluminium sheets for hot stamping

2018 ◽  
Vol 190 ◽  
pp. 08002
Author(s):  
Yankang Tian ◽  
Libo Wang ◽  
Gerald Anyasodor ◽  
Yi Qin
Keyword(s):  
Induction Heating ◽  
Numerical Study ◽  
Hot Stamping ◽  
High Energy ◽  
Heating Process ◽  
High Heating Rate ◽  
Heating Efficiency ◽  
Depth Analysis ◽  
Metal Sheets ◽  
Aluminium Sheets

Induction heating is one of the most popular metal heating technologies because of its high heating rate and high energy efficiency. This method is suitable for heating workpieces/blanks in different shapes, sizes and materials. Induction heating of metal sheets has been investigated by various research organizations and industrial companies. However, information concerning the induction heating of aluminium blanks is limited. Further, investigations were required by industries to address the issues relating to the uneven temperature distributions developed in the metal sheets so that an optimized design could be developed to help the enhancement of the technology. Aiming at the study of the induction heating process for hot stamping, especially the temperature distribution developed in the aluminium sheets, this paper presents in-depth analysis of induction heating using 3D FE simulations, involving uses of DEFORM and COMSOL. Different coil arrangements, level of powers, frequencies, cycle times, etc. have been modelled and simulated to examine their effects on the heating efficiency and developed temperature profiles in the Aluminium sheets. It is revealed from the simulations that design features in the induction coils like shapes of cross-sections and angles of coil corners affect the uniformity of the developed temperatures in the metal sheets. Heating with an optimized combination of the coil design and the power setting could help to achieve higher heating rates and temperature uniformity. Nevertheless, the application could be constrained by some practical factors.

scholarly journals Heating schemes and process parameters of induction heating of aluminium sheets for hot stamping

2019 ◽  
Vol 6 ◽  
pp. 17
Author(s):  
Yankang Tian ◽  
Libo Wang ◽  
Gerald Anyasodor ◽  
Zhenhai Xu ◽  
Yi Qin
Keyword(s):  
Induction Heating ◽  
Process Parameters ◽  
Hot Stamping ◽  
High Energy ◽  
High Heating Rate ◽  
Heating Efficiency ◽  
Depth Analysis ◽  
Metal Sheets ◽  
Power Setting ◽  
Aluminium Sheets

Induction heating is one of the most popular metal heating technologies due to its high heating rate and high energy efficiency. This method is suitable for heating workpieces/blanks in different shapes, sizes and materials. Although induction heating of metal sheets has already been investigated by various research organizations and industrial companies, information concerning the induction heating of aluminium blanks is limited. Considering that hot stamping of aluminium sheets for automotive and aerospace applications is currently attracting a lot of attentions, it is timely important to gain more understanding on this technology by conducting in-depth investigations. Especially, investigations are required to address issues relating to the uneven temperature distributions developed in the metal sheets when they are heated, so that optimum designs could be obtained to improve the technology and its applications. This paper presents an in-depth analysis conducted recently for the investigation into heating schemes and process parameters in induction heating of aluminium sheets, mainly using 3D FE simulations, based on a general experimental validation. Different material, coil geometric and power-setting factors were considered during the modelling and analysis to examine their effects on the heating efficiency and developed temperature profiles. It was revealed from the simulations that design features of the induction coils affect the uniformity of the developed temperatures in the metal sheets. It is shown that an optimised combination of the coil design and the power setting could help to achieve higher heating rates, at the same time, also to achieve higher temperature-distribution uniformity. At the end of this paper, a discussion of practical factors that affect applications of induction heating of aluminium sheets for hot stamping applications is presented.

Study on Three Dimensional Direct Coupling Simulation of Induction Heating for Hot Stamping

2014 ◽  
Vol 1063 ◽  
pp. 280-289
Author(s):  
Yong Li ◽  
Xiong Liang ◽  
Zhao Dong Wang ◽  
Jia Dong Li ◽  
Tian Liang Fu
Keyword(s):  
Induction Heating ◽  
Hot Stamping ◽  
Three Dimensional ◽  
Sheet Thickness ◽  
High Energy ◽  
Heating Time ◽  
Direct Coupling ◽  
Heating Process ◽  
High Energy Consumption ◽  
Frequency Current

As to the conventional hot stamping furnance’s shortcomings of long heating time, easy oxidized, high energy consumption, the application of induction heating for hot stamping were studied. By using COMSOL Multiphysics software, we calculated the electromagnetic induction field and temperature field by use of the direct coupling (Direct Coupling Method) in the heating process of hot forming sheet and studied the influence of inductor device parameters (such as induction length, distance between inductor and sheet etc.) and various process parameters (such as the power supply frequency, current density, sheet thickness etc.) on heating rate and temperature distribution. That will have a good guidance on the application of induction heating to hot stamping field.

A numerical study of the effect of the number of turns of coil on the heat produced in the induction heating process in the 3d model

2018 ◽  
Vol 18 (3) ◽  
pp. 408-419
Author(s):  
A J shokri ◽  
M H Tavakoli ◽  
A Sabouri Dodaran ◽  
M S Akhondi Khezrabad ◽  
◽  
...  
Keyword(s):  
Induction Heating ◽  
3D Model ◽  
Numerical Study ◽  
Heating Process

scholarly journals Experimental and numerical study of the effect of coil structure on induction nitriding temperature field

2020 ◽  
Vol 12 (7) ◽  
pp. 168781402093848
Author(s):  
Kangjie Song ◽  
Jing Guan ◽  
Kunmao Li ◽  
Jing Liu
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Induction Heating ◽  
Current Density ◽  
Numerical Study ◽  
Radial Temperature ◽  
Current Frequency ◽  
Variable Pitch ◽  
Variable Radius ◽  
Heating Efficiency

The axial and radial temperature distributions of an induction heating workpiece considerably impact the subsequent nitriding process. To obtain a satisfactory temperature distribution, an equal pitch coil, a variable pitch coil, and a variable radius coil were designed. Furthermore, an induction heating model that exhibits electromagnetic and temperature field coupling was established; thus, the effects of the current density and frequency on the heating efficiency and temperature distribution of the workpiece were analyzed and compared. In addition, an induction heating experiment was conducted to verify the model. According to the numerical results, the variable radius coil can reduce the axial temperature difference in comparison with equal pitch coil and variable pitch coil. Hence, the workpiece heated using the variable radius coil can achieve a better temperature distribution when compared with those heated by the equal pitch coil and variable pitch coil, with appropriate current density and current frequency values.

scholarly journals Numerical study of Single-turn and Multi-turn coil effect in the induction heating process

2017 ◽  
Vol 4 (ICBS Conference) ◽  
pp. 178-186
Author(s):  
Abdoljabbar Shokri ◽  
Hamed Heydari ◽  
Muhammed Jameel Asaad
Keyword(s):  
Induction Heating ◽  
Numerical Study ◽  
Heating Process ◽  
Single Turn

scholarly journals Research on a New Localized Induction Heating Process for Hot Stamping Steel Blanks

Materials ◽  
2019 ◽  
Vol 12 (7) ◽  
pp. 1024
Author(s):  
Li Bao ◽  
Jingqi Chen ◽  
Qi Li ◽  
Yu Gu ◽  
Jian Wu ◽  
...  
Keyword(s):  
High Temperature ◽  
Induction Heating ◽  
Temperature Region ◽  
Hot Stamping ◽  
Lath Martensite ◽  
Water Quenching ◽  
Heating Process ◽  
Phase Zone ◽  
Two Phase ◽  
Steel Blank

Localized induction heating with one magnetizer was experimentally analyzed in order to investigate the altering effect of the magnetizer on the magnetic field. A 22MnB5 blank for tailored property was locally heated to produce the parts of a car body in white, such as the B-pillars. A lower-temperature region with a temperature in the two-phase zone and a full-austenitic high-temperature region were formed on the steel blank after 30 s. After water-quenching, the mixture microstructure (F + M) and 100% fine-grained lath martensite were obtained from the lower- and high-temperature regions, respectively. Moreover, the ultimate tensile stress (UTS) of the parts from the lower- and high-temperature regions was 977 and 1698 MPa, respectively, whereas the total elongations were 17.5% and 14.5%, respectively. Compared with the parts obtained by conventional furnace heating–water quenching (UTS: 1554 MPa, total elongation: 12%), the as-quenched phase developed a tensile strength over 100 MPa greater and a higher ductility. Thus, the new heating process can be a good foundation in subsequent experiments to arbitrarily tailor the designable low-strength zone with a higher ductility by using magnetizers.

Induction Heating of an Aluminum Billet: A Numerical Study of the Thermal Behavior

2011 ◽  
Vol 110-116 ◽  
pp. 4697-4704
Author(s):  
U. Ray ◽  
A. Sarkar ◽  
S. Sen ◽  
B. Roychowdhury ◽  
N. Barman
Keyword(s):  
Induction Heating ◽  
Source Term ◽  
Numerical Study ◽  
Control Volume ◽  
Momentum Conservation ◽  
Conservation Equation ◽  
Heating Process ◽  
Energy Conservation Equation ◽  
Transfer Behavior ◽  
Volume Method

In the present work, the heat transfer behavior during induction heating of a cylindrical aluminum billet is performed numerically. The heating process is represented by the energy conservation equation where the heat generation during heating is added as a volumetric source term. The evolution of latent heat during melting is also added as a volumetric source term. The continuity and the momentum conservation equations are considered to represent the flow field after melting starts. These governing equations are solved based on the control volume method. The enthalpy update scheme is used for evolution of melt-fraction during heating. The work predicts the evolution of temperature during heating, the distributions of temperature and melt-fraction in the domain. Subsequently, a parametric study is also performed.

Influence of Thermal History on Microstructure and Mechanical Properties of Steels for Hot Stamping

2010 ◽  
Vol 654-656 ◽  
pp. 330-333 ◽  
Author(s):  
Takehide Senuma ◽  
Yoshito Takemoto
Keyword(s):  
Mechanical Properties ◽  
Heating Rate ◽  
Heating Temperature ◽  
Hot Stamping ◽  
High Strength ◽  
Heating Process ◽  
High Heating Rate ◽  
Transformation Behavior ◽  
Microstructure And Mechanical Properties ◽  
Heat Treated

Hot stamping is an attractive method to produce extra high strength automotive components. In the conventional hot stamping, the furnace heating is employed and the heating rate is quite low. To improve the productivity of the hot stamping technology, the reduction of time for the heating process is required. In this study, the influence of the heating rate in a range up to 200°C/s, heating temperatures between 650°C and 950°C and cooling condition on microstructure and mechanical properties of 0.22% C -3%Mn steel has been investigated. The steel is a promising material for the highly productive new hot stamping technology because this steel transformed into martensite from austenite even at cooling in free air. The specimens heat-treated at a high heating rate and for short holding time at the heating temperature just above Ac3 show significantly fine martensite microstructure and a good strength-toughness balance. In this paper, the α→ γ transformation behavior and the γ→ α transformation behavior after inter-critical annealing are discussed to explain the evolution of the microstructures and mechanical properties.

Experimental rapid surface heating by induction for injection molding of large LCD TV frames

2014 ◽  
Vol 34 (2) ◽  
pp. 173-184 ◽  
Author(s):  
Shih-Chih Nian ◽  
Che-Wei Lien ◽  
Ming-Shyan Huang
Keyword(s):  
Standard Deviation ◽  
Injection Molding ◽  
Heating Rate ◽  
Induction Heating ◽  
Simulation Software ◽  
High Heating Rate ◽  
Mold Surface ◽  
Temperature Uniformity ◽  
Heating Efficiency ◽  
High Heating

Abstract The use of electromagnetic induction heating on achieving high mold temperature has been proven to effectively improve the appearance quality of injection molded parts. However, until now, the method has only successfully been used on heating small mold surfaces. This study aims to apply the method on a large injection mold that is used for producing 42-inch LCD TV frames. With the goals of achieving heating efficiency and uniformity, the main focus in this research is designing the induction coil. Initially, three types of induction coils – a single-layered coil with currents that flow in one direction, a single-layered coil with currents that flow in opposite directions, and a two-layered coil – were compared to confirm their heating rates; the best one was then chosen. Additionally, evaluation of various induction coils was preceded with commercial simulation software that supports electromagnetic and thermal analyses. An experiment involving heating a simple workpiece with a heated area similar to that of the male mold plate of the LCD TV frames was conducted to confirm its heating rate and uniformity. Real injection molding LCD TV frames assisted with induction heating was then carried out. Experimental results depicted that: (1) a single-layered coil with currents that flow in one direction performed best; (2) that it heated the simple workpiece at a high heating rate of 5.5°C/s with reasonable temperature uniformity (standard deviation: 5.1°C); and (3) induction heating of a 42-inch LCD TV frame mold surface in practical injection molding provided a high heating rate of 4.5°C/s with favorable temperature uniformity (standard deviation: 4.0°C).

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