Induction Heat Treating

Transcription

1 Induction Heat Treating xxx October 2013 Philippe Wendling Create, Design, Engineer! Our Problem A Load A Coil A Power Supply A Process An Environment All included in a power distribution system. 2 1

2 Our Problem Electrical, Magnetic, Thermal, Power Electronics, Mechanical, System, 3 Modeling Induction Heating We need: Precise Geometry Power Supply Process Description Materials Material Characteristics Electro-Magnetic Thermal Cooling Nonlinear Curie Temperature 4 2

3 Modeling Induction Heating FEM Tool: Geometry 5 Modeling Induction Heating FEM Tool: Mesh 6 3

4 Modeling Induction Heating Parameters: Optimization Design Characterization 7 Material properties 5,0E+06 Electrical Conductivity 25 Relative permeability 4,0E Sigma (S.m-1) 3,0E+06 2,0E+06 1,0E+06 0,0E Température ( C) mur Température ( C) 8 4

5 Magnetic Permeability relative permeability of steel depends on: magnetic field (H) and the temperature (T). 9 Material Properties Thermal conductivity decreases as temperature rises. phase transition energy at Curie point. 10 5

6 Modeling Induction Heating Power Supply 11 Results: Power Density 12 6

7 Results: Line Current Current Phase 13 Temperature Variation 14 7

8 Thermal Effect on EM Properties Resitivity Permeability 15 Hardening of Flange (Steel) 16 8

9 The Domain 2 dimensional axi-symmetric model. Induction Heating Technology and Applications FEM Domain: Geometry FLANGE INDUCTOR 1 INDUCTOR

10 FEM Domain: Mesh 19 Computation #1 Power Supply to Inductor: 4 khz 20 10

11 4 khz: Thermal Image at 9.75 s. 21 Computation #2 Power Supply to Inductor: 13 khz 22 11

12 13 khz: Thermal Image at 9.75 s. 23 Why Coupled Problems Current density map at the beginning of the heating process

13 Why Coupled Problems Current density map at the end of the heating process. 25 Why Coupled Problems Relative permeability Mur distribution at end of the heating process

14 Computation #3: New Geometry 27 4 khz: Thermal Image at 10.0 s

15 13 khz: Thermal Image at 10.0 s. 13 khz 29 Current Density vs. Time 30 15

16 Hardness Profile Induction Heating Technology and Applications Scanning Translating Motion Coupled Magneto-thermal Power supply Motion: inductor scans the component

17 Continuous Heating of Tubes Steel Tube (ferromagnetic) Heated T0 1,100 C. Moving Inside an Inductor 33 Power Density Distribution 34 17

18 Temperature Profile 35 Modified Inductor Grouping Turns 36 18

19 Complex Process Heat, Hold Heat Frequency #1 Start Hold Heat Frequency #2.n Hold Quench - Cool End 37 Complex Process Heat, Hold 38 19

20 3D Thermo-electromagnetics Application to heat treatments Cylinder Gear Crankshaft 39 3D Heat Treatment of Cylinder Validation of 3D Applications 40 20

21 2D/3D Domains 2D Geometry 3D Geometry Symmetry axis Cylinder (steel) Coil (copper) Support (stainless) Cylinder (steel) 41 Model Temperature Map 3D Geometry Heating time : 2 s Cooling by shower 1/8th of the device Full Geometry Temperature distribution (heating 2 s) 42 21

22 Results - Comparisons Comparison Flux3D / Flux2D (2D axi.) / measurements Flux 3D: Nodes: 6000 Elements: (T4+H8) CPU time: 9 h Flux 2D: Nodes: 2000 Elements: 900 (Q8) CPU time: 5 min Température ( C) Temperature vs. Time at 2 selected points during heating and cooling phases 1 mm depth 3 mm depth Mesures Mesures Simu. Flux3D MT Simu. Flux3D MT Simu. Flux2D MT Simu. Flux2D MT Temps (s) 43 Heat Treatment of a Gear Induction Heating Technology and Applications

23 Model - Domain Heating time : 9 s Cooling by shower Support (stainless) Coil (copper) Gear (steel) 45 Results at the end of the heating Temperature - Permeability Temperature distribution (heating 9 s) r (t=9 s) 46 23

24 Temperature vs. Time Comparison Flux3D / measurements Nodes : 8500 Elements : (T4+H8) CPU time : 16 h Temperature vs. Time Sommet / entrée - Mesure Sommet / entrée - Simu Pied (1mm) / milieu - Mesure Pied (1mm) / milieu - Simu Sommet / milieu - Mesure Sommet / milieu - Simu Pied (2mm) / milieu - Mesure Pied (2mm) / milieu - Simu Heat treatment of a crankshaft 48 24

25 Geometry Modelisation of the rotation of the crankshaft Crankshaft Nodes : Elements : (T4) CPU time : ~ 50 h Coil t = 0 s t = 0.5 s 49 Results Thermal and metallurgical (Flux Metal7) results Temperature distribution at the end of the heating Hardenesses distribution at the end of the heat treatment 50 25

26 Thank you for your interest in our modelling solutions