Induction heating processes are commonly used to harden, anneal and bond metals. Induction processes are attractive because they include the following advantages:
* Induction heating is clean – no contaminants are introduced and parts can be contained in vacuum or inert gas chambers.
* Induction heating is highly consistent and controllable, so is ideal for automation.
*Induction heating is versatile – it can be adapted to suit a wide range of metals and processes.
Best Solution’s expertise includes the use of 2 or 3-dimensional finite element methods to model induction heating. Magnetic, thermal and stress effects are accurately represented in a full simulation of the process and together with our customers, we can develop optimised induction heating parameters. The methods we use can be used to address important unknowns for many customers using induction heating, including answers to the following questions:
- Assessment of component design – how does the geometry of the component behave when subjected to an induction heating process?
- How suitable is the heat distribution – is power being absorbed in the right places, and how could the process or the component be changed to improve matters?
- What is the cycle time and power efficiency of the process?
- How can cycle time be reduced cost-effectively?
- What coil geometries are feasible – can a good compromise be achieved between ideal power distribution and other considerations?Best Solution can show full animations of the induction heating cycle, with graphical output including temperature rise vs time, cooling rates and component power density. Our models are parametric where possible, and this gives us the flexibility to run multiple scenarios and optimise with minimum effort.