The Process of Induction Forging and its Advantages

Bar End Heater for Forging

In this article, we will explore the process of induction forging and its advantages. So, let’s begin with the basic definition of induction forging.

What is Induction Forging?

induction forging
induction forging

In metal processing industries, induction forging is a process in which an induction heater is utilized to

pre-heat a metal piece before its shaping using a press or hammer. In the process of induction forging, a metal is typically heated to a temperature between 1100 °C (2010 °F) and 1200 °C (2190 °F), and then shaped and manipulated using a press or hammer.

Therefore, we can define induction forging in simple words as a metal shaping and manipulation technique that uses electromagnetic induction heating to pre-heat the metal workpiece.

Process of Induction Forging

Induction billet heater for forging application
Induction billet heater for forging application

The step-by-step process of induction forging is explained below:

Step 1 – Heating of Metal Workpiece:

Firstly, the metal workpiece is heated by using electromagnetic induction heating. In this process, an alternating electric current is made to flow through an electromagnetic coil that produces a changing magnetic field. The metal workpiece is placed inside the coil. The changing magnetic field links to the metal workpiece and induces eddy currents in it. Due to the flow of eddy current and electrical resistance effect, the metal piece heated up rapidly. The heating of the metal workpiece is done to increase its malleability.

Step 2 – Forging Operation of the Metal Workpiece:

After heating up the metal workpiece to the desired temperature, it is quickly moved to the forging press or hammer. The heated and malleable metal is then shaped and manipulated by using specialized tools and dies as per the desired specifications.

After getting an overview of the process of induction forging, let us now discuss its major advantages.

Advantages of Induction Forging

The major advantages of induction forging are explained below:

(1). Induction forging provides fast and efficient heating of metal workpieces:

The induction forging process involves the use of an electromagnetic induction heating process to heat up the metal workpiece. Electromagnetic induction heating is a fast and efficient method of heating metals. Hence, induction forging requires shorter heating time due to the quick temperature rise of the metal.

(2). Induction forging provides more precise control of temperature:

Induction forging uses electromagnetic induction heating which is a highly controllable heating process that provides precise control over the increase in temperature of the metal workpiece. This results in an accurate and consistent outcome.

(3). Induction forging is an energy-efficient process:

Induction forging is an energy-efficient process due to lesser losses of energy during the heating of the metal workpiece by induction heating process. This is because, induction heating directly heats up the metal workpiece, resulting in reduced energy wastage.

(4). Induction forging provides uniform heating and better consistency in final results:

The electromagnetic induction heating process provides uniform heating of the metal workpiece that helps in obtaining consistent results. Due to uniform heating of the workpiece, temperature variations are minimized which ensures consistency in the final product.

(5). Induction forging does not produce harmful byproducts:

Induction forging is a clean and environment-friendly process of metal shaping. It does not produce any kind of waste products that harm the environment.

(6). Induction forging reduces scale formation and oxidation of metal workpieces:

Induction forging involves a relatively shorter heating time, resulting in reduced scale formation and oxidation on the metal workpiece. In induction forging, localized heating of the workpiece is used, which also minimizes scale formation and oxidation. This in turn results in the reduced requirement for surface cleaning and treatment. Further, it improves surface quality.

(7). Induction forging helps to preserve the metallurgical properties of the metal workpiece:

Induction forging provides rapid heating, controlled temperature rise, and uniform heating that help to reduce the risk of thermal degradation and preserve the desired metallurgical properties of the metal workpiece.

(8). Induction forging is highly versatile:

Induction forging can be used to shape and manipulate various metals and alloys, making it versatile. Due to its high versatility, induction forging is used in a wide range of industries, including the energy industry, automotive industry, aerospace industry, etc.

(9). Induction forging can be integrated with automation systems:

Induction forging can be combined with automated control systems, resulting in increased efficiency, speed, consistency, and scalability in manufacturing and production.

(10). Induction forging provides a safer working environment:

Induction forging does not use the combustion of fuels and open flames to heat the metal workpiece. Hence, this minimizes the risk of fire and accidents and provides a much safer environment to work.

Conclusion

In conclusion, this is all about the process of induction forging and its advantages. The advantages of induction forging mentioned above make it a preferred choice for various metal process applications. In metalworking industries, it helps in improving quality, safety, and efficiency.

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