PRESENTATION ON

INDUCTION HEATING
GROUP
TWO

Induction heating
what is induction heating?
It is a process used to bond , harden or soften
metals or other conductive materials
It heats metal parts without any physical
contact ,open flame and loud noise
it offers an attractive combination of speed ,
consistency and control

Background of induction heating

its basic principles have been understood and
applied to manufacturing since 1920
during world war 2,the technology developed
rapidly to meet urgent war time requirements for
a fast and reliable process to harden metal
engine parts

What makes induction heating unique?

No torch or open flame is directly applied to the
metal part
Heat is actually induced with in the part (metal)
itself by circulating electrical current
heat is transferred to the metal through
electromagnetic waves (RF)
It is repeatable and controllable process

How induction heating works?

Set up

Inductor with metal

How induction heating works?

It works on basic principles of electricity
a solid state RF power supply sends an ac
current through an inductor
the part (metal) to be heated is placed inside
the inductor
the inductor serves as transformer primary
and the metal as secondary

How
as the metal part enters the magnetic field
circulating eddy currents are induced within the
metal
these eddy currents flow against the electrical
resistivity of the metal
this generates precise and localized heat with
out any direct contact between the metal and
inductor

How?
this heating occurs with both magnetic and non
magnetic parts (joule effect)
additional heat is produced within magnetic
parts through hysteresis
hysteresis is an electrical resistance to the
rapidly changing magnetic fields
this produces internal friction which in turn
produces heat

Important factors to consider

1. The characteristics of the part (metal)
metal or plastic
- plastics and other non conductive
materials can often be heated indirectly
by first heating the conductive metal
magnetic or non magnetic
- it is easier to heat magnetic materials
because they produce additional heat
through hysteresis effect

Important
thick or thin
- small or thin parts generally heat more quickly
than large thick parts, especially if the larger
parts need to be heated all the way through
this is because
-heating effect occurs on the surface or skin of
of the part (85%)

Important
resistivity
- Metals with strong resistance to the
current flow, builds up heat quickly
- Low resistivity metals such as copper,
aluminum take longer to heat ,so
- a very hot piece of steel will be more
receptive to induction heating than a cold
piece

Important
2.Inductor design
- A well-designed inductor provides the
proper heating pattern for your part and
- maximizes the efficiency of the induction
heating power supply
3.Power supply capacity
-The size of the induction power supply
required for heating a particular part can
be calculated

Important
-First, determine how much energy needs to
be transferred to the work-piece
-This depends on
mass of the material to be heated
specific heat of the material
rise in temperature required
heat losses should be considered
4. Degree of temperature change required

Important
-more induction heating power is generally utilized
to increase the degree of temprature change

Advantage of induction heating

optimized consistency
-once the system is properly set up, the
heating pattern is repeatable and
consistent
maximize productivity
this is due to
-it works so fast then heat is developed
directly and instantly

Advantage
-start up is instantaneous
-no warm up or cool cycle is required
improved product quality
-it decreases distortion , reject rates of
the product because
-no contact between the part to be
heated and inductor
increases fixture life

Advantage
-it only delivers site-specific heat to small area
of the part with out heating any surrounding parts
environmentally sound
-it is clean and non polluting process
-no smoke, no waste heat ,no loud noise
-non conductive materials are not affected
reduce energy consumption
-it needs no warm up and cool down
then heat loss is decreased

Disadvantage
it is expensive
WHY RIGRT DESIGN OF THE INDUCTOR?
with the right design
-it is possible to heat conductive materials
at any size and form
-it is possible to heat only the required
portion of the material
- temperature uniformity can be achieved

Basic construction of inductor

-they are often made up of copper (very
good conductor of heat and electricity)
-they can have single or multiple turns
-they are most often custom made to fit the
shape and size of the part to be heated
-they are cooled by circulating water
-placing the part (metal) close to the inductor
increases the flow of current and the

BASIC
amount of heat induced in the part ~ this
relationship of the part and the inductor is
called Coupling efficiency of the inductor

THE END

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