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.

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 Simulation study on modified coil configuration used for shrink fitting of semi-built-up crankshaft and parameters influencing the thermal distribution

2020 ◽  
Vol 103 (4) ◽  
pp. 003685042096785
Author(s):  
Jianguo Duan ◽  
Qinglei Zhang ◽  
Xintao Long ◽  
Kebin Zhang
Keyword(s):  
Temperature Distribution ◽  
Induction Heating ◽  
Three Dimensional ◽  
Element Model ◽  
Heating Process ◽  
Current Frequency ◽  
Dimensional Finite Element ◽  
Shrink Fitting ◽  
Three Dimensional Finite Element

Semi-built-up crankshafts are universally manufactured by shrink-fitting process with induction heating device. The configurations of induction coil have a great impact on the distributions of eddy current and temperature of crankthrows. Most induction devices are apt to cause some undesirable phenomena such as uneven temperature distribution and irregular deformation after induction heating. This article proposes a modified configuration of induction heating coil according to the crankthrow geometry. By combining the heat conduction equation and the heat boundary conditions, a three-dimensional finite element model, which takes into account the nonlinearity of the material’s electromagnetic and thermal physical properties in the heating process, was developed. The influence of several parameters, such as position and curvature of the arc coil, the current frequency and density, coaxiality of crankweb hole and coil, influencing the temperature distribution inside the crankthrow was also analyzed. The comparison with the numerical simulation results of the original configuration indicates that the modified configuration has better adaptability to the crankthrow. Also, it can help to improve the temperature distribution, and reduce the deformation of the shrink-fitting hole. This exploration provide an effective way for the enterprise to further enhance the shrink-fitting quality of crankshaft.

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.

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.

Process Design for Specific Applications

1988 ◽  
pp. 85-141
Keyword(s):  
Heat Treatment ◽  
Induction Heating ◽  
Heating Surface ◽  
Heating Time ◽  
Surface Heat ◽  
Heating Process ◽  
Workpiece Material ◽  
Design Considerations ◽  
Selection Of ◽  
Related Design

Abstract The detailed heating requirements for specific applications must be considered before construction and implementation of any induction heating process. These requirements may include considerations such as type of heating, throughput and heating time, workpiece material, peak temperature, and so forth. The major applications of induction technology include through heating, surface heating (for surface heat treatment), metal melting, welding, brazing, and soldering. This chapter summarizes the selection of equipment and related design considerations for these applications.

Numerical Simulation on Induction Heating Process for Crankshaft Shrink Fitting

2012 ◽  
Vol 215-216 ◽  
pp. 1111-1117
Author(s):  
Qing Lei Zhang ◽  
Bai Yu Zhao ◽  
Jing Kuan Guo
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Induction Heating ◽  
Heating Process ◽  
Technological Parameters ◽  
Effect Factors ◽  
Large Size ◽  
Heating Device ◽  
Shrink Fitting ◽  
Frequency Current

Based on induction heating theory, a finite elementmodel for electromagnetic-temperature field has been developed. The simulation of induction heating process in large size crankshaft shrink fitting is carried out by using FEA software ANSYS. With temperature and deformation distribution being calculated, the characteristics and effect factors in the induction heating process are also analyzed. In conclusion, the optimized crankshaft heating techonology could be estabished by adjusting technological parameters of the heating device. Specifically, frequency, current, heating position, etc.

Finite Element Analysis of Slab Steel in the Process of Induction Heating

2008 ◽  
Vol 575-578 ◽  
pp. 282-287 ◽  
Author(s):  
R.B. Mei ◽  
Chang Sheng Li ◽  
B. Han ◽  
Xiang Hua Liu
Keyword(s):  
Finite Element ◽  
Induction Heating ◽  
Low Frequency ◽  
Heating Time ◽  
Initial Time ◽  
Heating Process ◽  
Steel Mill ◽  
Element Analysis ◽  
Steel Temperature ◽  
Good Agreement

The induction heating process of slab steel had been discussed by finite element method. The results obtained were in good agreement to the measured value. In addition, the low-frequency induction heating process of slab steel was investigated and analyzed in detail according to the practice requirements of a steel mill. During the heating process of slab steel by low-frequency induction, the temperature increasing speed of surface is faster than that of center in initial time. With the increment of heating time, the temperature increasing speed of surface becomes lower because of the heat loss of boundary. A 90 percent of the slab steel temperature had risen from 1100°C to 1400°C with 110Hz and 6.2×106A/m2 after 30min, which could be satisfied with heating requirements.

Influencing Intermetallic Layers of Hot Stamped Steel for Adhesively Bonded Plastic Metal Hybrids

2019 ◽  
Vol 801 ◽  
pp. 258-263 ◽  
Author(s):  
Michael Demes ◽  
Jan Beuscher ◽  
Markus Kühn ◽  
Klaus Dröder
Keyword(s):  
Lightweight Design ◽  
Hot Stamping ◽  
Sheet Thickness ◽  
Automotive Application ◽  
Heating Process ◽  
Coating Performance ◽  
Lap Shear ◽  
Hybrid Specimen ◽  
Hot Stamped Steel ◽  
Intermetallic Layers

Hot stamping of high strength steel parts is an established way to realize today ́s structural lightweight components in car bodies through sheet thickness reduction. The steel typically used for hot stamping is a boron-manganese 22MnB5 steel reaching up to 1,900 MPa in strength. New boron-manganese alloys achieving higher strength are expected to be developed, generating challenges for the manufacturing process by means of formability. Thus, a further reduction of steel thickness resulting in lighter components is not expected. Hybrid lightweight design approaches aim at weight reduction by reducing steel thickness and applying fiber-reinforced plastics (FRP) to regain structural stiffness and strength. The use of residual heat remaining from the hot stamping process allows to activate adhesives to bond FRP to hot stamped steel. The performances of adhesive bonds depend strongly on surface characteristics. To avoid scaling and decarburization during the heating process several coatings for hot stamped steels are used forming intermetallic layers through heat treatment. The most common coating in today’s automotive application is an Al-Si coating. Thus, the overall performance of the adhesive bonded hot stamped metal polymer hybrid is not only depending on adhesives performance but also strongly on the hot stamped steel’s coating performance. In this paper, the characteristics of hot stamped steel 22MnB5 Al-Si coating are investigated with regard to adhesion performance. Therefore, hot stamped specimens are manufactured under realistic industrial conditions investigating the influence of furnace temperature and dwell time on the overall coating and intermetallic layers of Al-Si coating. The specimens are investigated with respect to Al-Si coating thickness, lap shear strength of hybrid specimen and tensile strength of hot stamped steel demonstrating the dependency of the overall hybrid specimen performance from the coating performance.

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