Design And Fabrication Of Inductors For Induction Heat .

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ASM Handbook, Volume 4C, Induction Heating and Heat TreatmentV. Rudnev and G.E. Totten, editorsCopyright # 2014 ASM InternationalWAll rights reservedwww.asminternational.orgDesign and Fabrication of Inductors forInduction Heat TreatingRob Goldstein, FluxtrolWilliam Stuehr, Induction ToolingMicah Black, Tucker Induction SystemsFOR INDUCTION MELTING AND MASSHEATING, the early induction heating coilswere manufactured from copper tubing wrappedin multiple turns around a mandrel. The firstinduction heat treating coils were developed forcrankshaft hardening in the 1930s (Fig. 1, 2)(Ref 1–4). Unlike the melting and mass heatingcoils, the heat treating induction coils weremachined. These inductors consisted of twoparts with a hinge on one side that would openand shut around the crankshaft journal. Quenchholes were drilled on the inner diameter of theinduction coil to deliver quench to the part afterheating. This pioneering development was theculmination of many years of hard work by alarge team and clearly demonstrated the differentrequirements for induction heat treating as compared to melting and mass heating.During the infancy of induction heat treatingcoil development, the specific features of the induction coil primarily were determined throughan analytical-, experience-, and experimental-Fig. 1Tocco coil. Source: Ref 1based method. Concepts for induction coils werecreated by physicists. Calculations of coil parameters were determined by manually solvingcomplex equations. Induction coil designs initially were made by draftsmen on blueprints.Most inductors were manufactured by craftsmen using a combination of copper tubing,manually machined components, and copperplates brazed together. Coil optimization wasmade based on experimental results throughthe trial-and-error method, because tests andmodifications took much less time than thecalculations did (Ref 1, 5).While many induction heat treating coils arestill manufactured in this way, the tools forthe design and fabrication of complex inductionheat treating inductors have evolved greatlyover the years. For many types of applications,the preferred induction coil style already isknown based on years of empirical data. Inmany cases, comparisons to known results caneven determine induction coil dimensions thatwill lead to a successful heat treating pattern,greatly limiting experimental testing times andshortening development cycles (Ref 1, 5–9).For newer applications or optimization ofexisting ones, computer modeling tools are beingincorporated into the induction coil designprocedure. Sophisticated software running onFig. 2Vologdin coilpersonal computers is capable of making calculations in seconds, minutes, or hours thatwould have taken days, weeks, or months tosolve manually. In many cases, no analyticalformula exists for complex coils, and the onlyway to make calculations prior to tests is witha computer modeling program. Induction coildesigns and process recipes are “virtually”tested to determine resulting heat patterns. Inmany cases today (2013), virtual tests and evaluations can be made more quickly and at alower cost than physical ones (Ref 10–12).The process of mechanical induction coildesign also has evolved over the years. Whilethe initial drawings were made by hand, inductioncoils now are drawn and detailed using computeraided design (CAD) packages. Over the past several years, CAD packages have increased theirinteractivity with computer-aided manufacturing(CAM) software packages. In many instances,induction coil drawings can be transferred froma CAD drawing to a CAM program into the computer numerically controlled machine. This creates the possibility for greater repeatability ofcomplex machined induction coils (Ref 13, 14).Methods of Induction Heat TreatingToday (2014), there are many different typesof induction heat treating coils. The inductionheat treating coil style depends on the inductionheat treating process. All induction heat treatingprocesses can be classified in two categories:single shot and scanning, based on whether theinduction coil is moving (excluding rotation)relative to the part during the heating process.A brief description is given subsequently, becausemore in-depth information on induction heattreating equipment is discussed in other sectionsin this article.In single-shot (Fig. 3) induction heat treatingapplications, the position of the inductioncoil relative to the heated length of the partdoes not move. In many single-shot heating

590 / Equipmentapplications, the part rotates while heating andquenching occur to ensure uniformity of pattern.Within the family of single-shot heat treatingapplications, there are several varieties of induction coil configurations, depending on thequench-delivery mechanism.Machined integral quench (MIQ) installationshave quench integrated right into the inductioncoil itself. The most common method is for thequench to be delivered through the coil copperitself. These inductors typically have separatepockets for water cooling and quench delivery.In some other cases, the quench may be delivered through a magnetic flux concentrator.Another type of single-shot heat treating installation is quenching in place (Fig. 4). Quenching inplace is similar to MIQ, because the quench ring isa part of the induction coil assembly. What differentiates quenching in place from MIQ installations is that the quench is not designed to be anactive component of the induction circuit.The final single-shot induction heat treatingcoil style is separate quenching (Fig. 5). Inthese installations, the quench is not part ofthe induction coil assembly. In separate-quenchinstallations, the quenching often is delivered ina different station or position in the machine.These systems are common when a delaybetween heating and quenching for heat soaking is desirable.Besides single shot, the other type of induction machine is scanning (Fig. 6) (Ref 5, 9). Inscan-hardening applications, the induction coilmoves relative to the part. Similar to single-shotinductors, scanning inductors can be either MIQor quenching in place. They also may be separate quenching, but this is less common.Considerations for Inductor DesignInduction heat treating coils are available inmany shapes and sizes and must perform a variety of tasks in a given induction heat treatingapplication. Depending on the application, theinduction coil design requirements include: Meet heat treatment specifications in desiredproduction rates Be robust enough to tolerate manufacturingvariations Mount into the induction machine Have electrical parameters that match the induction power supplyDeliver quenchHave a satisfactory lifetimeHave satisfactory efficiencyBe repeatable from inductor to inductorIn developing a new induction heat treatingcoil and process, the first question is whetherthe component will be produced on an existingsystem or if a new machine must be built. Inmany cases, the part producer’s desire is todevelop new tooling for an existing machinewith spare capacity. This reduces the degreeof freedom and can make the induction coildesign procedure more complicated, becausea less-than-optimal frequency or coil style willbe necessitated to fit the existing machine(Ref 16).To determine the ability to use existingequipment, it is necessary to make an analysisof the part to be heat treated. Part material,prior processing, geometry, production rate,and heat treatment specifications all play roles.The part material and prior processing determine what the minimum heat treatment temperature should be, along with how much time isallowed for cooling. The part geometry andheat treatment specifications indicate howmuch energy is required, what the preferredfrequency ranges are, and what type of induction method (i.e., single shot, scanning) is bestsuited for the application. Finally, the production rate determines how much power and/orhow many spindles or stations are required.More details on this topic are given later inthis and other articles in this Volume. The discussion in this article is limited to the relationship between these factors and the inductioncoil design.Current Flow in the PartFig. 3Single-shot induction heat treating applicationFig. 4Quench-in-place inductor for hardening of a spindleFig. 5Separate quenching. Source: Ref 15Fig. 6Machined integral quench scanning inductorwith magnetic flux concentratorEddy currents are the primary source ofpower dissipation in most induction heat treating applications. Eddy currents, just like allother electrical currents, must form a closedcontour. In most cases, the current flow in theworkpiece follows the shape of the inductionheating coil, due to the proximity effect. Thepower density in a given section of the workpiece depends on the current density. Thecurrent density can be influenced by electromagnetic effects (end effect, edge effect, etc.),the presence of magnetic flux concentrators,the width of the copper, the geometry of thepart, and the distance between the coil and theworkpiece (coupling gap).The next step in the coil design process isdetermining how the current will flow in thepart. This is critical, especially in cases wherethe geometry changes. Some common geometrychanges encountered in induction heat treatingare fillets, undercuts, corners, shoulders, chamfers, splines, keyways, and oil holes. The heating of these critical areas relative to adjacentones is strongly dependent on the induction coilstyle and frequency of heating.The first primary choices for current flow,either in the plane of the geometry change orperpendicular to the geometry change, are discussed here. When current flow is perpendicular to the direction of a geometry change, thenatural tendency is for the current to concentrate on the part surface that is closer to the

Design and Fabrication of Inductors for Induction Heat Treating / 591induction coil, due to the proximity effect. Anadditional consideration is that near the ends ofthe closer section to where the distance increases,there is either a decrease or an increase in heating, depending on whether the part is magneticor nonmagnetic due to the electromagnetic endeffect. For hardening applications, there is someincrease, and for tempering there is a decrease.The magnitude of the change depends on thefrequency (Fig. 7) (Ref 12).When the current flow is in the direction of ageometry change, the current flows under theinductor in a width approximating that of theinduction coil. When the dimension changeoccurs, the current flow follows the contour ofthe part through this dimensional change. Atthe point of the dimension change, the changein heating is governed by the electromagneticedge effect. The edge effect tends to be smallerthan the end effect, hence meaning a smallertemperature differential in this area. As the distance between the coil and part increases, theamount of current remains nearly the same,Fig. 7but the current begins to flow over a widerlength. The less concentrated heating leads tolower power densities (Fig. 8). The differencebetween the power densities tends to be smallerthan when current flow is in the direction of thegeometry change than when it is perpendicular.To illustrate the concept, consider the case ofa simple spindle with one bearing race and ashoulder (Fig. 9). The heat treating pattern isthe light-gray area. This part could be heatedeither by scanning or single shot. The scanninginductor almost certainly would be an encircling inductor with a length less than the pattern length. Within single shot, it also couldbe hardened by a machined encircling inductoror a so-called encircling/nonencircling inductor.For an encircling inductor (scanning or singleshot), the current flow in the coil and part tendto take the shortest path and flow along theinductor inside diameter and bearing surfacediameter. To compensate for this tendency,it is necessary to vary the gap between thecoil and part to use the proximity effect tocompensate for the shorter length for currentflow. In the area of the radius, there is a transition from the smaller gaps on the flange to thelarger gaps on the diameter. For a single-turnmachined inductor, the coil design in this areainvolves a delicate balance to achieve sufficientdepth in the fillet without heating too deeply inthe bearing area just above the fillet. For casedepths that are large relative to the cross section, this becomes more difficult because coretemperatures increase, resulting in reduced conductive heat extraction. For a shorter scanningcoil, this task is made easier by using a magnetic flux concentrator to drive current downfrom the shaft and into the radius of the part(Fig. 10).Encircling/nonencircling inductors consist ofmultiple partial loops connected by copper railsthat are contoured to the part surface (Fig. 11).For these inductors, the part must rotate toensure even heating. For a simple part such asthis, likely only one top and one bottom partialloop would be required. In this case, currentflows under the coil turns and follows the contour of the coil in the part. In this way, the topand bottom of the pattern are controlled by theend loops, and the rails determine the pattern inthe central area. By following the rails along thepart surface, the current flows through the radius.End-effect drawingFig. 9Fig. 8Edge-effect drawingFig. 10Heat pattern for spindleEncircling drawing for spindle

592 / EquipmentThis makes achieving a more uniform contoureasier with a linear inductor than with an encircling one for this type of part (Fig. 12).The Influence of FrequencyThe frequency of the induction heating current has a strong influence on the induction coiland process design. It affects the powerrequired, heating time, coil losses, local distribution of power in the part, and the structuralsupport required. A brief overview of the effectof frequency is given in this section, because itis covered in more depth in other articles in thisVolume.Often, the same case depth can be achievedover a wide range of frequencies. For largeparts in either the completely magnetic (coldsteel) or nonmagnetic (hot steel) state, currentdensity is highest at the surface and falls offFig. 11exponentially in depth. There is a value usedby induction heating practitioners called thereference or skin depth related to this behavior.The formula for reference depth is:d¼krffiffiffiffiffirmf(Eq 1)where d is the reference depth, k is a constantdepending on units, r is the electrical resistivity, m is the magnetic permeability, and f isfrequency.In large bodies, 63% of the current and 86%of the power reside in the first reference depth(Fig. 13) (Ref 6, 17). This leads to the assumption commonly made in estimating parametersthat all of the power is generated in the d layer.In induction hardening applications, thedistribution of current and power density is different than that predicted by the referencedepth, because the magnetic steel below theEncircling/nonencircling drawing for spindleCurie point still interacts with the magneticfield behind the nonmagnetic hot surface layer(Ref 17). To achieve the same case depth onparts with lower frequencies, one can expecthigher power levels, shorter heating times, andlower surface temperatures. As the frequencyis increased, power levels must be decreasedand heating times increased to achieve the samecase depth without overheating the surface. Theamount of energy required depends on the balance between thermal losses (heat soaking), coilefficiency, and power induced in the subcasedepth material.Besides the process, the frequency also influences how the current is flowing in the induction coil itself. In practice, the most effectivethickness of the conductive part of the tubingwall (d1) is assumed to be d1 ffi 1.6d1. Thisratio is based on solution of a one-dimensionalproblem. An induction coil tubing wall smallerthan 1.6d1 results in reduction in coil efficiency; furthermore, in some cases the tubingwall can be much thicker compared to theaforementioned ratio. This is because it maynot be mechanically practical to use a tubingwall thickness of 0.25 mm (0.01 in.). Someguidelines for wall thickness are shown inTable 1 (Ref 9).The frequency also affects the electrodynamic forces, which influence the mechanicaldesign of the induction coil. Electrodynamicforces in induction heating have two components: static and dynamic. The static componentinitially pulls the inductor in toward the part inthe cold magnetic state and then pushes it awayfrom the part when it is nonmagnetic. Thedynamic component oscillates around the staticcomponent at double the electric frequency(Fig. 14). The level of force in the system isproportional to the square of the coil current;that is, the forces are directly proportional tothe power (Ref 17).When the part is electrically thick (i.e., thediameter or thickness is much greater thanthe reference depth), the current required forthe same power is proportional to the inversefourth root of the ratio of frequencies (Eq 2).From this equation, it can be seen that the current required for the same amount of powerdecreases with increasing frequency:I2 ¼ I1sffiffiffiffif14f2Table 1tubing(Eq 2)Standard wall thickness of copperCopper wall thicknessmmFig. 13Fig. 12Linear/single-shot drawing for spindleDistribution of current (S) and power density(Pv) in the depth of a large workpiece.Source: Ref 170.75–11–21.5–44–6.5Source: Ref 7in.Frequency, 0.250450–5025–8.310–33–1

Design and Fabrication of Inductors for Induction Heat Treating / 593Due to this, the electrodynamic forces arehigher at lower frequencies. Additionally,power levels generally tend to be higher atlower frequencies, increasing the electrodynamic forces even more. Therefore, the lowerthe frequency, the more robust the mechanicaldesign of the induction coil should be. In addition to heavier copper wall thicknesses, the coilsupporting structure also must be stronger towithstand the mechanical loading to whichthe coil is exposed. This is especially true onsingle-shot coils.Control of Heating in DifferentAreas of the PartIn many induction heat treating applications,there is a requirement to selectively hardensome areas of the workpiece and not hardenothers. In other instances, different case depthsare desired in different areas of the part. Often,it is necessary to achieve these various targetsin the same induction heat treating operation.For scan hardening applications, these variations typically are compensated for by adjustingthe power and scan speed as the part traversesthrough the induction coil. For single-shotinduction coils, it is necessary to accommodatethese changes in the coil design. There are threemain tools for adjustment of the coil design:coupling gap, coil copper profile, and magneticflux controllers.The coupling gap is the most straightforwardway to control the heat pattern. The closer thecoil is to the part, the greater the intensity of heating in this area relative to other areas. This isbecause the current in the part flows in a narrower band more closely approximating that inthe induction heating coil. With increasing coupling gap, the current spreads out over a longerlength, resulting in lower current density andpower density.Another method to control the heat pattern isto change the cross-sectional profile of the copper coil. The section(s) of the coil turn thatfaces the part and carries the majority of theFig. 14Diagram showing relationship between current(i), static component of force (Fc), and dynamicforce (F ). Source: Ref 17current is referred to as the heat face of thecoil. For induction coils with a single heatface, power profiling is achieved by varyingthe geometry of the heat face (Fig. 15). Forinstance, to shorten the transition zones at theends of the coil, it is common to have a largergap in the middle of the coil than on the ends.This method is commonly used for controllingthe end of a heat treat

this and other articles in this Volume. The dis-cussion in this article is limited to the relation-ship between these factors and the induction coil design. Current Flow in the Part Eddy currents are the primary source of power dissipation in most induction heat treat-ing applications. Eddy currents, just like all

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