Simulation of induction systems of complex configurations for forging technologies

A detailed analysis of some induction heaters for forging processes is carried out taking into account energy efficiency and quality of heating. Complex configuration of the forging induction heaters needs in general case to use 3D-programs to solve the coupled electrical and thermal problems. Authors propose a new approach of 2D simulation for end parts of cylindrical billets in the oval and channel coils. It is shown that user oriented program 2DELTA is suited to simulate many heating applications before forging. Both electrical and thermal analyses are essential to a success of forging technology. Electrical analysis can give information about “end electromagnetic effects” of workpiece and inductor, optimal frequency of power source, design of induction coils and supplying circuits to increase electrical efficiency. Thermal analysis permits to obtain the quality of heating and maximum total efficiency. The results of simulation for cylindrical billets are presented.