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Forging is a traditional metal processing technology that uses the pressure generated by an impact hammer to shape metal. Cold forging is used to make smaller steel parts and softer materials. However, this process hardens the material and makes post-forging processing difficult.

In the hot forging process, the part is heated to above the material's recrystallization temperature before forging. This process enables parts to be molded with minimal pressure and produces finished parts with reduced residual stress, which is convenient for machining or heat treatment. In the warm forging process, the parts are forged below the recrystallization temperature, usually below 700°C. Figure 1 is a demonstration of induction heating.

Induction heating provides a better option than furnace heating because it can provide fast and efficient heat in forging applications. The process relies on current to generate heat within the part.

The high power density ensures instant heating and strictly controls the heating area. With the latest development of solid-state technology, induction heating has become a simple and low-cost heating technology.

Induction heating provides many benefits for forging applications. Compared with other heating technologies, it provides safe and reliable heating, promotes rapid heating to achieve higher output and higher productivity, ensures accurate and uniform heating of components, and reduces energy consumption.

The process is a clean non-contact heating method that can be easily integrated into the production unit. Generally, induction heating is used to heat metal blanks and bar ends before forging. Nevertheless, many factors must be considered when using induction heating in forging applications.

Factors such as the size of the heating component, radiation loss, and heating time should be considered.

Figure 2. Heating time.

In addition to the energy required to heat the part to the forging temperature, the size of the part also determines the operating frequency of the induction system to improve work efficiency.

In addition, in the production process of induction coils, due to radiation, the thermal part will lose a lot of energy. However, this can be controlled using insulation.

In addition, the induction process generates heat within the part, but the heat is generated near the outer surface and it takes time to reach the core of the part. Generally, it takes 150 seconds for a 75 mm diameter bar to heat to the center, while the end of a 20 mm diameter bar takes less than 10 seconds (Figure 2).

Figure 3. A screen view of the eVIEW software monitoring the hot upsetting process of fasteners, showing that a part is only heated to 750°C instead of the correct process temperature of 900°C. )

In the manufacturing of aerospace fasteners, the quality of the components, the consistency and repeatability of the production process are very important. In order to detect and record this process, Ambrell provides eVIEW software (Figure 3), which can be used to record the process data of each heating component.

The software captures the exact operating details of the sensing system, including temperature and other important process parameters.

Figure 4. Work unit with automatic feeding to large bolt thermal header.

Figure 5. The billet heater used to heat a 48 mm diameter x 350 mm long billet produces a billet every 12 seconds.

Billet heating is a process that requires the forging of entire parts, such as the production of automobile crankshafts, while in bar end heating, only one end of the part is forged, such as the production of hot upsetting fasteners and automobile steering parts.

Ambrell's modular induction heating system is specially designed for billet heating, with an operating frequency of 750 Hz to 15 kHz. Ambrell also offers a variety of induction heating products for heating the ends of bars. The company provides expertise in heating processes for the mass production of high-quality parts (Figures 4 and 5).

Ambrell's modular EKOHEAT induction heating system can be customized to run at the correct frequency for a specific forging process (Figure 6). The system can be configured for single heating up to 1.6 MW, and stage heating in steps of 50, 125, 250 or 500 kW. The system is equipped with a tapped transformer and multiple capacitor configurations and can be easily installed in the work area.

Ambrell provides enterprises with optimized induction heating solutions. The company's induction heating experts work with customers to understand their unique forging requirements and provide timely support before and after sales. Ambrell provides high-quality products and innovative solutions to maximize customer return on investment.

This information is derived from materials provided by Ambrell Induction Heating Solutions and has been reviewed and adapted.

For more information on this source, please visit Ambrell Induction Heating Solutions.

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Assume that the power supply of a billet heater is 150 kW/1250 Hz. Working diameter=25mm, length=300mm. What is the ID of the heating coil suitable for heating 25mm diameter billets? If we use a coil with an ID of 70mm, the coupling will be problematic due to the large gap between the coil and the working diameter. The result is 70-25/2=22.5mm

What is the heat source for forging?

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