Induction Forging Systems

Induction Forging Systems - Overview

Induction forging systems utilise the principles of electromagnetic induction to produce heat in a work-piece prior to deformation by a hammer or press. Induction heating offers the following benefits over more traditional methods.

Induction Forging Systems - Benefits

• Energy Efficiency – In the induction heating process the heat is within the component making energy transfer is extremely efficient. The induction heater heats only the part not the atmosphere around it.
  
  
• Improved Working Environment – As the heat is generated within the part and not the atmosphere the working environment is improved no open furnaces etc. Additional benefits are also seen as no products of combustion are produced leading to a cleaner process.
  
  
• Health & Safety Benefits – The induction heating process by its nature often improves working environment safety by removal of naked flames and gas from the production process.
  
  
• Rapid Temperature Rise - High power densities ensure that the component reaches temperature extremely rapidly. Scale is reduced as are surface defects and undesirable effects on the surface metallurgy. Throughput is often increased as the parts are presented to the operator at a predictable rate, therefore rather than the operator dictating throughput the system dictates the throughput.
  
  
• Process Consistency - The induction heating process produces extremely uniform consistent heat this improves accuracy of the forging and can in extreme cases reduce post forging machining allowances and have a positive effect on die life.
  
  
• Process Controllability - Unlike a traditional gas furnace the induction system requires no pre-heat cycle or controlled shutdown. The heat is available on demand. In addition to the benefits of rapid availability in the event of a downstream interruption to production the power can be switched off thus saving energy and reducing scaling on the components.

Induction Forging Systems - Applications

Bar End Heating Induction Forging

Bar end heating is typically used where only a portion of the bar is to be forged. Subject to the required throughput, handling systems can vary from simple 2 or 3 station pneumatic pusher systems to walking beams and conveyors. Typical applications of bar end heating are:

1. Hot heading of bolts
2. Anti roll bars
3. Mining tools
   

Billet Heating Induction Forging

In the induction billet heater the whole of the billet or slug is heated. Normally for short billets or slugs a hopper or bowl is used to automatically present the billets in line to pinch rollers, chain driven tractor units or in some cases pneumatic pushers. The billets are then driven through the coil one behind the other on water cooled rails or ceramic liners are used through the coil bore which reduce friction and prevent wear. The length of the coil is a function of the required soak time, the cycle time per component and the length of the billet. In high volume large cross section work it is not unusual to have 4 or 5 coils in series to give 5 m (16 ft) of coil or more. Typical parts processed by in line billet heating:

1. Small crankshafts
2. Camshafts
3. Pneumatic and hydraulic fittings
4. Hammer heads
5. Engine valves
   

Single Shot Induction Forging

For long billets, single shot heating can be used. This process utilises similar systems to bar end heating except that the whole of the billet is driven into individual coils. As with bar end heating the number of coils is governed by ?T required and the thermal properties of the material being heated. Typical parts processed by single shot billet heating:

1. Lorry axles
2. Marine camshafts

Please browse our website for more information about Inductelec Induction Edge Hardening then contact us on 0114 272 3369 to speak to a member of our team or e-mail us on info@inductelec.co.uk.