Induction Heat Treating xxx October 2013 Philippe Wendling philippe.wendling@magsoft-flux.com Create, Design, Engineer! www.magsoft-flux.com www.cedrat.com Our Problem A Load A Coil A Power Supply A Process An Environment All included in a power distribution system. 2 1
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
Modeling Induction Heating FEM Tool: Geometry 5 Modeling Induction Heating FEM Tool: Mesh 6 3
Modeling Induction Heating Parameters: Optimization Design Characterization 7 Material properties 5,0E+06 Electrical Conductivity 25 Relative permeability 4,0E+06 20 Sigma (S.m-1) 3,0E+06 2,0E+06 1,0E+06 0,0E+00 0 500 1000 Température ( C) mur 15 10 5 0 0 500 1000 Température ( C) 8 4
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
Modeling Induction Heating Power Supply 11 Results: Power Density 12 6
Results: Line Current Current Phase 13 Temperature Variation 14 7
Thermal Effect on EM Properties Resitivity Permeability 15 Hardening of Flange (Steel) 16 8
The Domain 2 dimensional axi-symmetric model. Induction Heating Technology and Applications 2006 17 FEM Domain: Geometry FLANGE INDUCTOR 1 INDUCTOR 2 18 9
FEM Domain: Mesh 19 Computation #1 Power Supply to Inductor: 4 khz 20 10
4 khz: Thermal Image at 9.75 s. 21 Computation #2 Power Supply to Inductor: 13 khz 22 11
13 khz: Thermal Image at 9.75 s. 23 Why Coupled Problems Current density map at the beginning of the heating process. 24 12
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. 26 13
Computation #3: New Geometry 27 4 khz: Thermal Image at 10.0 s. 28 14
13 khz: Thermal Image at 10.0 s. 13 khz 29 Current Density vs. Time 30 15
Hardness Profile Induction Heating Technology and Applications 2006 31 Scanning Translating Motion Coupled Magneto-thermal Power supply Motion: inductor scans the component. 32 16
Continuous Heating of Tubes Steel Tube (ferromagnetic) Heated T0 1,100 C. Moving Inside an Inductor 33 Power Density Distribution 34 17
Temperature Profile 35 Modified Inductor Grouping Turns 36 18
Complex Process Heat, Hold Heat Frequency #1 Start Hold Heat Frequency #2.n Hold Quench - Cool End 37 Complex Process Heat, Hold 38 19
3D Thermo-electromagnetics Application to heat treatments Cylinder Gear Crankshaft 39 3D Heat Treatment of Cylinder Validation of 3D Applications 40 20
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
Results - Comparisons Comparison Flux3D / Flux2D (2D axi.) / measurements Flux 3D: Nodes: 6000 Elements: 32000 (T4+H8) CPU time: 9 h Flux 2D: Nodes: 2000 Elements: 900 (Q8) CPU time: 5 min Température ( C) 1200 1000 800 600 400 200 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 0 0 1 2 3 4 5 6 7 Temps (s) 43 Heat Treatment of a Gear Induction Heating Technology and Applications 2006 44 22
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
Temperature vs. Time Comparison Flux3D / measurements Nodes : 8500 Elements : 28000 (T4+H8) CPU time : 16 h Temperature vs. Time 1000 900 800 700 600 500 400 300 200 100 1000 900 800 700 600 500 400 300 200 100 Sommet / entrée - Mesure Sommet / entrée - Simu 0 0 5 10 15 20 25 30 Pied (1mm) / milieu - Mesure Pied (1mm) / milieu - Simu 0 0 5 10 15 20 25 30 1000 900 800 700 600 500 400 300 200 100 0 1000 900 800 700 600 500 400 300 200 100 Sommet / milieu - Mesure Sommet / milieu - Simu 0 5 10 15 20 25 30 Pied (2mm) / milieu - Mesure Pied (2mm) / milieu - Simu 0 0 5 10 15 20 25 30 47 Heat treatment of a crankshaft 48 24
Geometry Modelisation of the rotation of the crankshaft Crankshaft Nodes : 15000 Elements : 80000 (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
Thank you for your interest in our modelling solutions www.magsoft-flux.com Philippe.Wendling@magsoft-flux.com Tan.Pham@magsoft-flux.com Heide.Lewis@magsoft-flux.com 51 26