Induction Heat Treating4 7 Modeling Induction Heating Parameters: • Optimization •Design •...
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1 Create, Design, Engineer! Induction Heat Treating xxx www.magsoft-flux.com www.cedrat.com October 2013 Philippe Wendling [email protected] 2 Our Problem A Load A Coil A Power Supply A Process An Environment All included in a power distribution system.
Transcript of Induction Heat Treating4 7 Modeling Induction Heating Parameters: • Optimization •Design •...
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Create, Design, Engineer!
Induction Heat Treating
xxx
www.magsoft-flux.comwww.cedrat.com
October 2013
Philippe [email protected]
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Our Problem
A Load
A Coil
A Power Supply
A Process
An Environment
All included in a power distribution system.
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Our Problem
Electrical,
Magnetic,
Thermal,
Power Electronics,
Mechanical,
System,
…
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Modeling Induction Heating
We need:
Precise Geometry
Power Supply
Process Description
Materials
Material Characteristics
Electro-Magnetic
Thermal
Cooling
Nonlinear
Curie Temperature
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Modeling Induction Heating
FEM Tool:
Geometry
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Modeling Induction Heating
FEM Tool:
Mesh
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Modeling Induction Heating
Parameters:
• Optimization
• Design
• Characterization
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0,0E+00
1,0E+06
2,0E+06
3,0E+06
4,0E+06
5,0E+06
0 500 1000
Température (°C)
Sig
ma
(S
.m-1
)
0
5
10
15
20
25
0 500 1000Température (°C)
mu
r
Material properties
Electrical Conductivity Relative permeability
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Magnetic Permeability
relative permeability of steel depends on:
– magnetic field (H)
– and the temperature (T).
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Thermal conductivity decreases as temperature rises.
phase transition energy at Curie point.
Material Properties
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Modeling Induction Heating
Power Supply
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Results: Power Density
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Results: Line Current
Current
Phase
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Temperature Variation
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Thermal Effect on EM Properties
Resitivity
Permeability
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Hardening of Flange (Steel)
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The Domain
Induction Heating Technology and Applications ‘2006
2 dimensional axi-symmetric model.
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FEM Domain: Geometry
FLANGE
INDUCTOR 1
INDUCTOR 2
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FEM Domain: Mesh
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Computation #1
Power Supply to Inductor:4 kHz
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4 kHz: Thermal Image at 9.75 s.
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Computation #2
Power Supply to Inductor:13 kHz
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13 kHz: Thermal Image at 9.75 s.
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Why Coupled Problems
Current density map at the beginning of the heating process.
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Why Coupled Problems
Current density map at the end of the heating process.
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Why Coupled Problems
Relative permeability Mur distribution at end of the heating process.
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Computation #3: New Geometry
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4 kHz: Thermal Image at 10.0 s.
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13 kHz: Thermal Image at 10.0 s.
13 kHz
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Current Density vs. Time
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Hardness Profile
Induction Heating Technology and Applications ‘2006
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Scanning– Translating Motion
Coupled Magneto-thermal
Power supply
Motion: inductor scans the component.
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Continuous Heating of Tubes
Steel Tube (ferromagnetic)Heated T0 1,100 °C.
Moving Inside an Inductor
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Power Density Distribution
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Temperature Profile
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Modified Inductor – Grouping Turns
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Complex Process – Heat, Hold
Start
Heat – Frequency #1
Heat – Frequency #2….n
EndQuench - Cool
Hold
Hold
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Complex Process – Heat, Hold
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3D Thermo-electromagneticsApplication to heat treatments
Gear CrankshaftCylinder
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3D Heat Treatment of Cylinder
Validation of 3D Applications
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2D/3D Domains
Support (stainless)
Coil (copper)
Cylinder (steel)
Cylinder (steel)
Symmetry axis
3D Geometry2D Geometry
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Model – Temperature Map
Temperature distribution (heating 2 s)
1/8th of the device
Full Geometry
Heating time : 2 s
Cooling by shower
3D Geometry
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Results - Comparisons
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200
400
600
800
1000
1200
0 1 2 3 4 5 6 7Temps (s)
Tem
péra
ture
(°C
)
MesuresMesuresSimu. Flux3D MTSimu. Flux3D MTSimu. Flux2D MTSimu. Flux2D MT
Comparison Flux3D / Flux2D (2D axi.) / measurements
Temperature vs. Time at 2 selected points during heating and cooling phases
1 mm depth
3 mm depth
Flux 3D:
Nodes: 6000 Elements: 32000 (T4+H8)
CPU time: 9 h
Flux 2D:
Nodes: 2000 Elements: 900 (Q8)
CPU time: 5 min
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Heat Treatment of a Gear
Induction Heating Technology and Applications ‘2006
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Model - Domain
Support (stainless)
Coil (copper)
Gear (steel)
Heating time : 9 sCooling by shower
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Temperature - Permeability
Temperature distribution (heating 9 s)
r (t=9 s)
Results at the end of the heating…
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Temperature vs. Time
0
100
200
300
400
500
600
700
800
900
1000
0 5 10 15 20 25 30
Sommet / entrée - Mesure
Sommet / entrée - Simu
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100
200
300
400
500
600
700
800
900
1000
0 5 10 15 20 25 30
Sommet / milieu - Mesure
Sommet / milieu - Simu
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100
200
300
400
500
600
700
800
900
1000
0 5 10 15 20 25 30
Pied (1mm) / milieu - Mesure
Pied (1mm) / milieu - Simu
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100
200
300
400
500
600
700
800
900
1000
0 5 10 15 20 25 30
Pied (2mm) / milieu - Mesure
Pied (2mm) / milieu - Simu
Comparison Flux3D / measurements
Temperature vs. Time
Nodes : 8500
Elements : 28000 (T4+H8)
CPU time : 16 h
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Heat treatment of a crankshaft
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Geometry
Nodes : 15000Elements : 80000
(T4)CPU time : ~ 50 h
t = 0 s t = 0.5 s
Modelisation of the rotation of the crankshaft
Crankshaft
Coil
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Results
Temperature distribution at the end of the heating
Hardenesses distribution at the end of the heat treatment
Thermal and metallurgical (Flux – Metal7) results
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