In metal processing industries, forging is a process used for forming and shaping metals by the application of heat and compressive forces. In metal forging, the heat can be delivered by using a heating system like gas furnace, induction heating system, etc. and the compressive forces are provided by hammering or pressing.
Introduction to Induction Forging System
A type of metal forging system in which an induction heating system is involved to preheat the metal workpiece and then shaped by using a hammer or press is referred to as an induction forging system.
In simple words, a metal forging system with an induction heater is called an induction forging system.
In an induction forging system, the heat required for preheating of the metal is generated by utilizing the principle of electromagnetic induction and joule’s law of heating.
(1). Principle of Electromagnetic Induction:
The principle of electromagnetic induction states that when a changing magnetic links to a metal/conductor, it induces a varying emf in the conductor. The magnitude of this emf is given by,
Where, e is the induced emf, ϕ is the magnetic flux, and N is the number of turn in the induction coil.
This induced emf causes a time-varying current to flow through the conductor which is given by,
Where, R is the electrical resistance of the conductor.
(2). Joule’s Law of Heating:
This law states that an electric current flowing through a metal/conductor produces heat due to its electrical resistance. This generated heat is given by,
Induction Forging Process: Step-by-Step Explanation
The induction forging process involves the following steps:
Step 1 – The inductor coil of an induction heating system is energized by passing a high-frequency alternating current through it. This produces a changing magnetic field around the coil.
Step 2 – The metal workpiece is then placed within the changing magnetic field produced by the induction coil.
Step 3 – The changing magnetic field induces electric currents (called eddy currents) within the body of the metal workpiece through electromagnetic induction, resulting in the heating of it due to the effect of electrical resistance.
Step 4 – Finally, once the metal’s temperature is reached to a desired value, the workpiece is formed and shaped by using a hammer or press.
Today, induction forging is the most commonly used forging technique in various industries, including automotive manufacturing, aerospace, oil and gas, and other metal processing industries.
Now, let us explore the benefits of induction forging systems, making them a better choice in multiple industries.
Induction Forging System Benefits
Induction forging systems offer several benefits that make them a better choice for metal forging applications by enhancing metal properties, improving productivity, and reducing the manufacturing cost. Some key benefits of induction forging systems are listed below:
(1). Fast and Efficient Heating:
Induction forging system generates heat directly within the metal workpiece, resulting in the fast and efficient heating due to minimal energy loss. This also increases the production rate by reducing the preheating time.
(2). Uniform Heating:
Induction forging system provides precise and consistent temperature control, ensuring uniform heating of the metal workpiece throughout its cross-section. This increases strength and lifespan of the forge.
(3). Low Power Consumption:
Induction forging systems consume low power as compared to traditional forging systems. This is mainly due to direct and localized heating of the workpiece, resulting in the reduced energy loss. This advantage of the induction forging systems reduce the operational cost of the plant.
(4). Increased production Rates:
The combination of rapid uniform heating and efficient forming and shaping processes minimize the production time, and resulting in the increased production cycles.
(5). Enhanced Mechanical Properties:
The capability of consistent temperature control of induction forging systems enhances the mechanical characteristics like strength, toughness, etc. of the material. This allowing manufacturer to produce high-quality end products.
(6). Reduced Oxidation and Scaling of the Metal Surface:
Induction forging systems have shorter heating period and localized heating that reduce the oxidation and scaling of the metal surface. This enhances the finishing of the surface and eliminates the time and cost involved in additional surface treatment.
(7). Versatility:
Induction forging systems can be used for forming and shaping processes of various metals, such as steel, copper, aluminum, and different types of alloys. This versatility of induction forging systems makes them a better choice in various industries, such as manufacturing, automobile, oil and gas, aerospace, metallurgy, and more.
In conclusion, induction forging system is an efficient way of metal forging used in various metal processing industries. It provides affordable forging solutions with reduced heating time, versatility, lower energy consumption, and improved material properties. Therefore, induction forging system is considered as an advanced metalworking equipment which combines the induction heating and efficient shaping processes together.
