This document presents a project that aims to develop a semi-automatic forging process using induction heating technology. It does so to improve upon traditional forging techniques by decreasing production lead times and fuel consumption while improving product quality, productivity, and environmental sustainability. The project involves designing an induction heating system integrated with a hydraulic press forging unit and automatic robotic handling system. It provides details on the principles and benefits of induction heating, challenges with traditional furnaces, and discusses the system components and their design. The goal is to optimize the forging process using lean manufacturing principles.

1. INTRODUCTION TO THE
PROJECT
One of the sole purposeof Mechanical Engineering is to:
Develop and optimize various manufacturing processes & developing
new and more economically viable manufacturing processes.
We have incorporated various techniques of CAPP (Computer Aided
Process Planning ). One such vital and very much trending tool is Lean
Manufacturing process

3. PROBLEM STATEMENT
• What are the main drawbacks of traditional forging
techniques?
• Obsolete furnace design using fossil fuel to heat
hardly up to 900 c but has efficiency of about 30 %
• High fuel consumption rate decrease the
profitability.
• Inconsistent and non uniform heating.

4. TRADITIONAL FURNACES
• Non greenprocess.
• Waste disposal and furnace
maintenance.

5. INDUCTION HEATING - THE LEAN
GREEN ALTERNATIVE

7. AIM OF THE PROJECT
• By implementation of induction technology
• Decreasing lead time of production
• Optimized consistency
• Maximized productivity
• Improved product quality
• Environmentally sound
• Reduced energy consumption

8. “SEMI AUTOMATIC FORGING WITH
INDUCTION TECHNOLOGY”
The entire project can be classified into
three sub chapters and will be discussed
one after another as follows:
• Induction heating system
• Semi automatic Forging press system
• Automatic Robotic Handling system

9. INDUCTION HEATING SYSTEM

10. HYDRAULI
C PRESS
FORGING
UNIT

11. ROBOTIC MANIPULATOR

12. INDUCTION HEATING
APPLICATION

13. INDUCTION FURNACE

14. INDUCTION WELDING

15. • INDUCTION BRAZING

16. INDUCTION SEALING

17. HEAT TREATMENT

18. APPLICATION CONTINUED
• Forging industry application.
• Automotive and aerospace Industry Solutions
• Power Generation Industry Solutions
• Oil & Gas Industry Solutions
• Food Industry Heating Solutions
• Cable and Wire Heating Solutions
• Medical Device Manufacturing Solutions

19. THEORY

20. • Important Factors to Consider
• METAL OR PLASTIC
• MAGNETIC OR NONMAGNETIC
• THICK OR THIN
• RESISTIVITY
• Inductor Design
• Power Supply Capacity
• Degree of Temperature Change Required
IMPORTANT FACTORS TO BE CONSIDERED

21. Material Final temp.°C Efficiency
Carbon steel 1250 0.65
Carbon steel 700 0.80
Stainless steel 1250 0.60
Brass 800 0.50
Copper 900 0.40
Aluminum 500 0.40
efficiency of heat transfer in induction heating

22. FREQUENCY SELECTION FOR GIVEN DIAMETER AND
TEMPERATUE

23. • (1) From vacuum tube oscillator and
electronic generator
• (2) From spark-gap generator
• (3) From motor-generator set
• (4) From solid-state inverters
TYPES OF POWER SYSTEM

24. IGBT is the most suitable to be used as a power source.

25. GOVERNING EQUATION

26. SKIN DEPTH AT GIVEN FREQUENCY OF
CERTAIN MATERIAL

27. SIMULATION RESULTS

28. INDUCTOR DESIGN
• Material : copper
• No . Of turns :6
• Diameter of rod: 3 mm
• Applied frequency : 160 khz
• Temp of work piece : 900 degree C
• Electrical rating:220v ,10 A
• Time of heating: 30sec
• Power consumption : 2200 KW

29. Before calculating our energy requirements we first
need to know:
• • The type of material (steel, copper, brass, etc.)
• • Work piece dimensions
• • Desired hourly production
• • Desired final temperature

31. VIDEO ON HEATING

32. Hydraulic press forging system
• What is Press Forging?
definition:
• The shaping of metal between dies by mechanical or
hydraulic pressure. Usually this is accomplished with a
single work stroke of the press for each die station.

34. Working principle of press

35. FORGING FORCE

36. DIE DESIGN

37. DESIGN
All dimensions are in inch

38. Robotic manipulator

41. JOINT

42. ACTUATOR

43. Controller

44. ROBOTIC ARM DESIGN

45. ROBOT Geometry

46. FANUC code for the desired movement
• SPEED 60
• JOINT A1= 80.67 A2= -59.22 A3= 81.58 A4= -0.15 A5= -19.51 A6= 5.76
• GRIPPER OPEN
• JOINT A1= 80.67 A2= -50.15 A3= 72.51 A4= -0.15 A5= -19.51 A6= 5.76
• GRIPPER CLOSE
• SPEED 90
• JOINT A1= 2.15 A2= -63.5 A3= 75.52 A4= -0.15 A5= -0.97 A6= 5.75
• JOINT A1= 2.15 A2= -55.29 A3= 67.31 A4= -0.15 A5= -4.64 A6= 5.76
• WAIT 30000
• JOINT A1= 2.15 A2= -72.34 A3= 84.36 A4= -0.15 A5= -4.63 A6= 5.76
• WAIT 60000
• SPEED 100
• JOINT A1= 79.78 A2= -64.23 A3= 80.56 A4= -0.15 A5= -4.64 A6= 5.76
• JOINT A1= 79.78 A2= -59.32 A3= 75.65 A4= -0.15 A5= 62.19 A6= 5.76
• WAIT 20000
• GRIPPER OPEN
• WAIT 1000
• HOME_ALL

47. • Video

48. THEORITICAL ECONOMIC ANALYSIS:
Parameters Convention
al forging
Process:
COST Induction forging
process:
COST
Production
time.
90 min ----------- 35 min --------
Lead time : More Less
Fuel
consumption :
8-10 Kg coal
+ fuel oil+
Auxiliary
machinery
cost
Rs 4
@ RS 400/
ton coal+ RS
5 + Rs 6 =
Rs 15
Electricity=
1.16 KWh + .54
Kwh
Rs 8.50
@ Rs 7/ kWh
Polluting gases: Present Non green Absent Green
Accuracy : 30% ------------ 80% -----------
Efficiency : 40% ------------ 75% ------------
Rate of
production:
LOW HIGH
For making 10 square section from round bar by a single worker we adopted
two procedure for a study :

49. PROBLEMS WE MAY ENCOUNTER
• High initial cost of implementation.
• Critical electronic solid state circuit .
• Resonance matching required to get desired
heating effect.
• Skilled work force .

50. FUTURE SCOPE
• It is a new and emerging field in modern
manufacturing technology.
• Ample scope of research and development
with the coil design , die design , and
implementation of automation.
• Portability can be increased.
• Response to different material can be studied.
• Experimental validation of certain
hypothetical statements can be verified.