Program complex for optimization of surface hardening of steel billets

The aim of the paper is to develop program complex in software MATLAB with integrated numerical 2D nonlinear FLUX model, which is used for solving optimal inductor design and control problems for heating stage of surface induction hardening. Considered program complex is based on alternance method, that allows to write systems of transcendental equations, closed with respect to all unknown design and control parameters of the process. The suggestion for implementation of obtained optimal control algorithm is presented.

Optimal inductor design for surface hardening under conditions of interval uncertaity of process parameters

The paper is devoted to the optimal inductor design for surface hardening of steel cylindrical billets. The heating stage of surface induction hardening is considered as an object with distributed parameters, which unknowns are design characteristics of the induction installation. In real industrial conditions the main technological parameters are often defined by the intervals of their possible values. That is why, in the paper the optimal design problem under the conditions of interval uncertainty of initial billets temperature and thermal exchange coefficient is formulated. Solution of the formulated problem is carried out by alternance method of parametric optimization based on numerical model developed in Altair FLUX software.

Effective methods for optimal design of induction coils on example of surface hardening

Purpose This paper aims to describe main ideas and demonstrates results of the research activities carried out by the authors in the field of optimal design concepts for induction heater for surface hardening. The main goal of the research studies is the application of different optimization methods and numerical finite element method (FEM) codes for field analysis to solve the optimal design problem that is mathematically formulated in terms of the one of the most important optimization criteria for surface hardening technology, e.g. maximum temperature uniformity within the hardening surface layer. Design/methodology/approach Evolutionary algorithm based on Adaptive Gaussian Process-Assisted Differential Evolution for MEMS Design Optimization (AGDEMO) and alternance method of parametric optimization based on optimal control theory are applied as effective tools for the practice-oriented problem for optimization of induction heater design based on non-linear coupled electromagnetic and temperature field analysis. Different approaches are used for combining FEM codes for interconnected field analysis and optimization algorithms into automated optimization procedure. Findings Optimization procedures are tested and investigated for optimal design problem solution on the examples of induction hardening of steel cylindrical billet. Practical implications Solved problems are based on the design of practical industrial applications. The developed optimization procedures are planned to be applied to the wide range of real-life problems of the optimal design of different electromagnetic devices and systems. Originality/value This paper describes main ideas and results of the research activities carried out by the authors in the field of optimal design of induction heaters for hardening based on numerical coupled electromagnetic and temperature field analysis. The implementation of the automated procedure that combines a numerical FEM code for coupled field analysis with an optimization algorithm and its subsequent application for designing induction heaters makes the proposed approach specific and original. This paper also demonstrates that different optimization strategies used (evolutionary algorithm based on AGDEMO and alternance method of optimal control theory) are effective for real-life industrial applications for optimization of induction heaters design.