Automatic Feeding Type Induction Forging Machine For Bar Ends Heating

Automatic Feeding Type Induction Forging Machine For Bar Ends Heating

INDUCTION FORGING :

Induction forging is a method of forming metal parts by heating them before they are shaped either by pressing them between two blocks, or by hammering them.

Induction forging is a heating process used to shape and form metal parts by applying heat to a metal billet through electromagnetic induction. It involves passing an alternating current through a coil, creating a magnetic field that induces eddy currents within the metal workpiece placed in the coil, causing it to heat rapidly. The heated metal is then forged into the desired shape using a press or hammer.

 

 
Six Protection:

• Overcurrent Protection                 Water shortage Protection
• Overheating Protection                 Overvoltage Protection
• Short circuit Protection                  Phase Protection

The equipment includes a medium frequency induction heating machine, worktable, induction coil, feeding machine, Infrared temperature detector, and some other parts.

Features of medium frequency induction forging machine:

• Wide frequency range: 1KHZ—20KHZ, according to the diameter of the working piece to choose the suitable frequency.
•  When heating a whole piece of material, the length of the induction coil can be made from 500mm –1m, when heating multiple pieces, better penetrating results can be guaranteed.
• It adopts continuously heating method, with a uniform load in the induction coil, it can solve the problem of great voltage change in output power during the heating process when the temperature of the workpiece reaches 1100℃ from room temperature, by this way, actual output power can be always above 95% efficiency, thus the machine is effectively used.
• When heating bronze, aluminum, and other nonferrous metal, by suitable design of induction coil and capacitance, the actual output power of the machine can be above 85% efficiency than calculated.
• Compare with controllable silicon frequency machines, our equipment is of small size, easy maintenance, and can save power by approximately 15--20%.

Power selection of the induction heating for forging

• An induction heating for forging power supplies ranges in power from a few kilowatts to several megawatts, and its frequency can vary from 50 Hz to 200 kHz, depending on the component geometry. Most applications use the range between 1 kHz and 100 kHz.
• When selecting the correct power for the heating systems, it is necessary to determine the amount of thermal energy essential to heat the metal to the required temperature within the specified time.
• Calculating the weight of the metal, the time cycle, and its heat content can determine the heat content of this metal which is usually expressed in KW hours per tonne. This calculation must do this after other factors have been taken into account.

Frequency selection of the induction forging machine

• Another major parameter to consider is the power source’s output frequency.
• A frequency must be chosen that allows deep penetration into the material without risking the cancellation of current since heat is generated predominantly at the surface of the component. Because only the skin of the component will be heated, it will take time for the heat to penetrate all the way to the center. This can cause the surface of the component to melt while the core remains cool.
• Calculating or creating a model to determine the heat time required can be accomplished by using the thermal conductivity of the metal, along with the homogeneity (physics) requirements from the customers regarding the cross-sectional.
• Heating the components one at a time typically takes longer than heating them together. In order to facilitate heating multiple components at the same time whilst delivering single components to the operator at the required time, a number of handling solutions are utilized, such as conveyors, in-line feeders, and pusher systems.

THE ADVANTAGES OF INDUCTION FORGING:

Efficient Heating: Induction forging uses electromagnetic energy to heat metals quickly and efficiently. Unlike other heating methods like gas furnaces or resistance heating, induction heating can provide much faster and more uniform heating, reducing the time and energy required to forge the metal.

Consistent Quality: Induction heating provides precise temperature control, resulting in consistent and repeatable quality of the forged parts. This is particularly important in industries that require high-quality, reliable parts, such as aerospace, automotive, and medical device manufacturing.

Reduced Scrap: Induction forging reduces scrap by minimizing heat distortion and material waste during the forging process. Induction heating can also eliminate the need for preheating or post-heating processes, which can further reduce scrap and improve efficiency and productivity.

Safe and Clean: Induction heating is a safe and environmentally clean process that minimizes the risks associated with open flames and toxic fumes from traditional heating methods. It also generates less noise pollution and reduces the need for air conditioning due to the low amount of heat emitted from the equipment.

INDUCTION FORGING APPLICATION:

Mainly used for workpiece heating, the heating temperature is between 200-1400 degrees.

1, Pre-forging heating: applied to gear, ring gear, bearing, shackle, and rigging.

2, Online heating: Pipe anti-corrosion coating, long steel rod heating, steel (wire) tube online quenching, and tempering.

3, Local heating: U-bolt bending, thermal assembly of the drum, Steel pipe elbow, etc.