Induction Heat Treatment Presentation

8/11/2019 Induction Heat Treatment Presentation

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Engr. Rodnel O. Tamayo

Project Leader

ESTABLISHMENT OF INDUCTION HEATING

DESIGN AND DEVELOPMENT FACILITY

PCIEERD TP PRESENTATION



• Heat metal parts without physical contact..

• At speeds unheard of with conventional methods..

• With pinpoint accuracy and consistency..

•

Up to 90% efficiency..• Without open flames, loud noise or harmful fumes..

• Even in special environment (submerged in liquid, inert or reducing atmosphere orvacuum)

INTRODUCTION TO IHT PROJECT



• Bond, harden or soften metals or other conductive

materials;

• Understood and applied to manufacturing since 1920s;

• Fast, reliable process to harden metal engine parts

during WW2;

• Focus on lean manufacturing techniques and improved

quality control led to rediscovery of inductiontechnology, along with the development of precisely

controlled, all solid state induction power supplies

FACTS ABOUT INDUCTION HEATING

Aluminum brazing

Cap sealing



Hard brazing

Heat treatmentTool brazing

Tin soldering Warm forming

Case hardening



• Joule effect; heat with electrical current

• Hysteresis; electrical resistance of

magnetic materials resulting to internalfriction and heat

•

Material to be heated is isolated from thepower supply;

• Submerged in liquid, covered by isolated

substances, in gaseous atmosphere,

vacuum;

HOW INDUCTION HEATING WORKS



RADIATION HEATING

Resistance heating

• Heat and melts metals,welding, brazing and

selective surface heat

treatment

• Very localized and works fast

• Very poor temp control

• Significant temp differences

across heating zone

ALTERNATIVE SOURCES OF HEAT

CONDUCTIVE HEATING

Flame heating

• Brazing, soldering,hardening, hot forming, pre-

heating for welding, etc

• Gases and fumes

• Accuracy and consistency

issues

CONVECTION HEATING

Ovens and furnaces

• Pre-heating, annealing;brazing, heat treating,

sintering

• Space requirement

• Continuous operation

• Whole part heating

•

Loss of heat into the factory



• Produces the varying magnetic field needed

for induction heating

•

One of the most important aspects of theoverall induction heating machine

• Provides the proper heating pattern for

the part

•

Maximizes efficiency of the inductionheating power supply

• Allows easy insertion and removal of part

• Part and application specific; mass productionto justify investment

Coupling Efficiency

• Lower distance between the part – higher power

• Coupling efficiency vs part handling

Magnetic Flux Placement

• Maximum number of flux lines to the target area

• Prevent cancellation of magnetic field

• Use of flux diverters

Basic construction

• Made of copper tubing – very good conductor of

heat and electricity

• Cooled by circulating water

THE INDUCTOR



INDUCTION HEATING DESIGN AND DEVELOPMENT

SOUTIONSREQUIREMENTS

• Inductor design

• Part handling design

•Quenching design

• Power supply selection

• Atmosphere selection

• Monitoring and control system design

• …

• Part shape and

dimensions

•

Heating result• Production speed

• Cost efficiency

• Budget

• …

CONSIDERATIONS

• Electromagnetic, thermal, metallurgical,

chemical composition, microstructure, …

• Electrical, mechanical, electronics and

controls, …

• Power supply characteristics

•…



• Thermal, metallurgical

• Chemical

DESIGNING A CONVENTIONAL HEAT TREATMENT SYSTEM

• Part shapes and dimensions

• Heating result

• Production speed

• Equipment selection

• Part handling selection

• Power control

REQUIREMENTS SOLUTIONS CONSIDERATIONS



DESIGNING THE INDUCTOR COIL

Basic Steps Traditional Method Software Based Method

Design and build the inductor coil; Built on large empirical data,

experiences and “rules of the

thumb”;

Years of experiences and

proprietary data ;

Numerical simulation tools to

simulate and analyse effects of

design inputs;

Cost effective and fast

development

Run trials and conduct

metallographic analysis on the

parts;

Same Same

Modification of the inductor coildepending on the results of the

analysis;

Modification based onmetallographic analysis only;

More information as bases for themodifications



PROJECT OVERVIEW

Project Title

Establishment of Induction Heat Treatment Facility

Nickname

IHT Project

Project Leader

Rodnel O. Tamayo

Duration

2 years



RATIONALE

Year Automotive Related Export Automotive Related Import

Estimated Qty (kg) Estimated Amt (Php)

2006 1,285,280 128,528,000 24,540,100 2,454,010,000

2007 8.090.105 809,010,500 19,436,900 1,943,690,000

2008 3,171,840 317,184,000 42,109,400 4,210,940,000

2009 778,895 77,889,500 22,777,500 2,277,750,000

2010 140,725 14,072,500 72,901,400 7,290,140,000

2011 1,246,315 124,631,500 19,530,700 1,953,070,000

2012 5,402,410 540,241,000 63,722,400 6,372,240,000



OBJECTIVES AND DELIVERABLES

General Objectives

To establish an induction heat treatment design and development facility in MIRDC

Specific Objectives

To establish a facility that can design, simulate, fabricate and validate induction coil systems;

To design, fabricate and validate performance of at least 5 inductor coil

To design and fabricate an induction coil with the following characteristics

Capable of achieving the target case hardness – depth and profile on a component

Optimized for the existing power supply systems

Validated to meet the required heating pattern and metallurgical quality



EXPECTED OUTCOMES

Contribute to the competitiveness and sustainability of the metals and engineering sector

Develop capability in design, manufacture and validation of induction heating system

Enable access of machine and machine parts manufacturers to induction heating systems



BUDGETARY REQUIREMENTS

Expense Class Year 1 Year 2

PS 1,218,096 1,218,096

MOOE 2,680,000 4,130,000CO 14,045,804 0

TOTAL 17,943,900 5,348,096



TIMELINES

Objectives and Activities Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

Identification and acquisition of hardware, software, hire

personnel, ready utilities and location for the facility

Set up the equipment

Train key personnel in the design and simulation and analysis of

inductor systems

Identification of components to be heat treated; Identification of

the required hardness profile

Design, simulation, analysis, fabrication of inductor system for theidentified component

Validation of the performance of the inductor system by testing

and analysis of the hardness profile generated

Promotion of the facility to potential customers in the industry

Induction Heat Treatment Presentation

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