Computer Simulation of Induction Heating Process

Computer Simulation ofInduction Heating Processes Dr. Valentin Nemkov Mr. Robert Goldstein Centre for Induction Technology, Inc. Auburn Hills, MI USA

Overview• Benefits of Computer Simulation• Special Features of Induction Heating Computer Simulation• Induction Heating Computer Simulation Software• Rule of Pyramid• Computer Simulation Example

Computer Simulation Rules of Thumb• Works for Any • Good for Simple Geometry and Geometries Conditions • Don’t Provide a Good• Demonstrate the Understanding of the Entire Dynamics of Process the Process • Experience Isn’t• Leaves a Record for Passed On Future Study • Case Dependent• Limitless Accuracy Accuracy

Accuracy of Computer Simulation• Mainly Depends upon Description of Material Properties• Number, Distribution and Type of Elements• System Description

Why Isn’t there One Comprehensive Computer Simulation Software Package for Induction Heating?• Induction heating simulation involves a set of mutually coupled non-linear phenomena• Many induction applications are unique and may require individual program structures• Powerful personal computers with high processing speeds and large available memory only recently became available• The induction heating market is small compared to other industrial sectors• It is difficult to make an induction coil that doesn’t heat at all and some users don’t care about design optimization

Specific Features of Induction Heating Computer Simulation Process Control Machine Operating Mode Power Supply Circuits Thermal Process (Heating) Electromagnetic Process Cooling Quenching Stresses Structural Transformations Distortions

Types of Programs for Induction Heating Computer Simulation at CIT PC simulation programs Type Example 1D coupled Elta 2D Electromagnetic QuickField 2D Thermal Flux2D 2D Coupled Flux2D 3D Electromagnetic Flux3D 3D Thermal Flux3D

ELTA, 1-D Software Features• User Friendly Interface with Very Fast Solver• Electromagnetic + Thermal• Axisymmetrical or Plane Parallel Geometries• Database with Non-Linear Properties of Materials• Automatic Report Generation

Scanning Simulation Using ELTA

QuickField, 2-D Software Features• User Friendly Interface• Electromagnetic Only• Linear Materials Only• Fast Solver• Inexpensive

Flux 2D, Software Features• Less Friendly User Interface• Electromagnetic + Thermal• Material Database with Non-Linear Properties• Can Work in Conjunction with Other Software (AutoCad, MatLab, etc.)

Flux 3D, Software Features• Less Friendly User Interface• Electromagnetic or Thermal• Material Database with Non-Linear Properties• Tetrahedral, Cubic and Prizmatic Elements

3-D Simulation of HeatExchanger Joint Brazing

Rule of Pyramid 3D 2D, Electromagnetic + Thermal2D, Electromagnetic or Thermal1D, Electromagnetic + Thermal

Computer Simulation of Seam Annealing Process

Induction Seam Annealing• Removes Stresses and Improves Microstructure after Induction Seam Welding• High Production Rates, > 3 ft / s• One of Two Induction Coil Styles Used: Split-n-Return Vertical Loop• No Published Studies on Coil Style Selection

Case Study Conditions• Tube: 1040 Steel – 2” Diameter with 1/8” Wall• Frequency 10 kHz• Same Current Applied (2200 A)• Production Rate 3.8 ft / s• Flux Concentrator: Fluxtrol A

Half of Geometry Used For Simulation, 2mm Grid Vertical Loop Split-n-Return

Vertical Loop Inductors Magnetic Field LinesReturn Leg Same Tube Return Leg Wider Tube

Vertical Loop Inductors, Final Temperature Distribution Tmax 934 C Tmax 938 CReturn Leg Same Tube Return Leg Wider Tube

Vertical Loop Inductors, Flux Density in the ConcentratorReturn Leg Same Tube Return Leg Wider Tube

Split-n-Return Inductor Magnetic Field Lines

Split-n-Return Inductor Final Temperature Distribution Tmax 959 C

Split-n-Return Inductor, Magnetic Flux Density in Concentrator

Table of Results of SimulationStyle Coil V Coil I Coil Loss Tube P Max T Efficiency Total PowerVL Same 378 2200 36.0 216 934 85.7% 252VL Wide 321 2200 31.8 216 938 87.0% 248SNR 272 2200 31.1 236 959 88.0% 267

Results of Study on Seam Annealing• Both Induction Coil Styles When Properly Designed Work Effectively for the Seam Annealing Process• For Vertical Loop Inductors, a Wider Return Leg Should Be Used• Computer Simulation Is an Effective Tool for Prediction and Study of Induction Seam Annealing System Performance

Conclusions• There are Many Advantages of Using Computer Simulation• The Specific Features of an Induction Heating System must be Considered for Computer Simulation• The Rule of Pyramid is a Strategy for Limiting the Time Required for Simulation

Computer Simulation of Induction Heating Process

by Fluxtrol Inc. on Mar 20, 2012

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