Abstract: Induction assisted single point incremental forming
(IASPIF) is a flexible method and can be simply utilized to
form a high strength alloys. Due to the interaction between the
mechanical and thermal properties during IASPIF an evaluation for
the process is necessary to be performed analytically. Therefore, a
numerical simulation was carried out in this paper. The numerical
analysis was operated at both room and elevated temperatures
then compared with experimental results. Fully coupled dynamic
temperature displacement explicit analysis was used to simulated the
hot single point incremental forming. The numerical analysis was
indicating that during hot single point incremental forming were a
combination between complicated compression, tension and shear
stresses. As a result, the equivalent plastic strain was increased
excessively by rising both the formed part depth and the heating
temperature during forming. Whereas, the forming forces were
decreased from 5 kN at room temperature to 0.95 kN at elevated
temperature. The simulation shows that the maximum true strain was
occurred in the stretching zone which was the same as in experiment.
Abstract: Increasing demands of contemporary applications for high strength and lightweight materials prompted the development of metal-matrix composites (MMCs). After the discovery of carbon nanotubes (CNTs) in 1991 (revealing an excellent set of mechanical properties) became one of the most promising strengthening materials for MMC applications. Additionally, the relatively low density of the nanotubes imparted high specific strengths, making them perfect strengthening material to reinforce MMCs. In the present study, aluminum-multiwalled carbon nanotubes (Al-MWCNTs) composite was prepared in an air induction furnace. The dispersion of the nanotubes in molten aluminum was assisted by inherent string action of induction heating at 790°C. During the fabrication process, multifunctional fluxes were used to avoid oxidation of the nanotubes and molten aluminum. Subsequently, the melt was cast in to a copper mold and cold rolled to 0.5 mm thickness. During metallographic examination using a scanning electron microscope, it was observed that the nanotubes were effectively dispersed in the matrix. The mechanical properties of the composite were significantly increased as compared to pure aluminum specimen i.e. the yield strength from 65 to 115 MPa, the tensile strength from 82 to 125 MPa and hardness from 27 to 30 HV for pure aluminum and Al-CNTs composite, respectively. To recognize the associated strengthening mechanisms in the nanocomposites, three foremost strengthening models i.e. shear lag model, Orowan looping and Hall-Petch have been critically analyzed; experimental data were found to be closely satisfying the shear lag model.
Abstract: Induction heating computer simulation is a powerful tool for process design and optimization, induction coil design, equipment selection, as well as education and business presentations. The authors share their vast experience in the practical use of computer simulation for different induction heating and heat treating processes. In this paper treated with mathematical modeling and numerical simulation of induction heating furnaces with axisymmetric geometries for the numerical solution, we propose finite element methods combined with boundary (FEM) for the electromagnetic model using COMSOL® Multiphysics Software. Some numerical results for an industrial furnace are shown with high frequency.
Abstract: This paper presents a novel three-phase utility
frequency to high frequency soft switching power conversion circuit
with dual mode pulse width modulation and pulse density modulation
for high power induction heating applications as melting of steel and
non ferrous metals, annealing of metals, surface hardening of steel
and cast iron work pieces and hot water producers, steamers and
super heated steamers. This high frequency power conversion circuit
can operate from three-phase systems to produce high current for
high power induction heating applications under the principles of
ZVS and it can regulate its ac output power from the rated value to a
low power level. A dual mode modulation control scheme based on
high frequency PWM in synchronization with the utility frequency
positive and negative half cycles for the proposed high frequency
conversion circuit and utility frequency pulse density modulation is
produced to extend its soft switching operating range for wide ac
output power regulation. A dual packs heat exchanger assembly is
designed to be used in consumer and industrial fluid pipeline systems
and it is proved to be suitable for the hot water, steam and super
heated steam producers. Experiment and simulation results are given
in this paper to verify the operation principles of the proposed ac
conversion circuit and to evaluate its power regulation and
conversion efficiency. Also, the paper presents a mutual coupling
model of the induction heating load instead of equivalent transformer
circuit model.
Abstract: The induction hardening machines are utilized in
the industries which modify machine parts and tools needed to
achieve high ware resistance. This paper describes the model of
induction heating process design of inverter circuit and the results
of induction surface hardening of heating coil. In the design of
heating coil, the shape and the turn numbers of the coil are very
important design factors because they decide the overall operating
performance of induction heater including resonant frequency, Q
factor, efficiency and power factor. The performance will be tested
by experiments in some cases high frequency induction hardening
machine.
Abstract: Aiming the application of localized hyperthermia, a
magnetic induction system with new approaches is proposed. The techniques in this system for improving the effectiveness of localized hyperthermia are that using magnetic circuit and the multiple-coil array instead of a giant coil for generating magnetic field. Specially, amorphous metal is adopted as the material of magnetic circuit. Detail
design parameters of hardware are well described. Simulation tool is
employed for this work and experiment result is reported as well.
Abstract: The paper deals with determination of electromagnetic
and temperature field distribution of induction heating system used
for pipe brazing. The problem is considered as coupled – time
harmonic electromagnetic and transient thermal field. It has been
solved using finite element method. The detailed maps of
electromagnetic and thermal field distribution have been obtained.
The good understanding of the processes in the considered system
ensures possibilities for control, management and increasing the
efficiency of the welding process.
Abstract: This paper presents the study of hardness profile of spur gear heated by induction heating process in function of the machine parameters, such as the power (kW), the heating time (s) and the generator frequency (kHz). The global work is realized by 3D finite-element simulation applied to the process by coupling and resolving the electromagnetic field and the heat transfer problems, and it was performed in three distinguished steps. First, a Comsol 3D model was built using an adequate formulation and taking into account the material properties and the machine parameters. Second, the convergence study was conducted to optimize the mesh. Then, the surface temperatures and the case depths were deeply analyzed in function of the initial current density and the heating time in medium frequency (MF) and high frequency (HF) heating modes and the edge effect were studied. Finally, the simulations results are validated using experimental tests.
Abstract: This paper presents the study of induced currents and
temperature distribution in gear heated by induction process using 2D
finite element (FE) model. The model is developed by coupling
Maxwell and heat transfer equations into a multi-physics model. The
obtained results allow comparing the medium frequency (MF) and
high frequency (HF) cases and the effect of machine parameters on
the evolution of induced currents and temperature during heating.
The sensitivity study of the temperature profile is conducted and the
case hardness is predicted using the final temperature profile. These
results are validated using tests and give a good understanding of
phenomena during heating process.