250KW Medium Frequency Induction Forging Machine For Steel Bar Forging
INDUCTION FORGING :
An induction heating machine for forging is a device that uses electromagnetic induction to heat metal bars or billets to a plastic state before deforming them with a press or hammer. Induction heating for forging allows for fast and uniform heating of the metal, reducing energy consumption and improving product quality.
An induction heating machine for forging consists of an induction coil, a power supply, and a workpiece. The induction coil generates an alternating magnetic field that induces eddy currents in the workpiece. The eddy currents cause resistive heating and raise the temperature of the workpiece to the desired forging temperature. The workpiece can then be moved to a forging station where it is shaped by applying pressure or hammering.
| Specification | Max output power | Heating capability for common materials |
| GYM-250 forging furnace | 250KW | Recommending OD25-OD110mm steel bar heating |
Six Protection:
| MFP | GYM-40KW | GYM-80KW | GYM-100KW | GYM-120KW | GYM-160KW | GYM-200KW | GYM-250KW | GYM-300KW | GYM-400KW |
| Bar Diameter | 15~30(mm) | 15~50(mm) | 20~50(mm) | 20~50(mm) | 25~80(mm) | 25~100MM | 25~110MM | 40~120(mm) | 40~140(mm) |
| Production Rates | 0.1~0.12(T/h) | 0.2~0.25(T/h) | 0.2~0.25(T/h) | 0.2~0.3(T/h) | 0.3~0.37(T/h) | 0.4~0.6(T/h) | 0.4~0.65(T/h) | 0.7~0.8(T/h) | 0.8~0.9(T/h) |
| Output Power | 40KW | 80KW | 100KW | 120KW | 160KW | 200KW | 250KW | 300KW | 400KW |
| Input Current | 60A | 120A | 150A | 180A | 240A | 300A | 375A | 450A | 600A |
| Work Frequency | 1~20KHZ | ||||||||
| Work Power | 380V/50~60HZ 3phases | ||||||||
| Duty Cycle | 24Hours non-stop | ||||||||
| Dimension | Customs Design depends on bar size | ||||||||
Features of medium frequency induction forging machine:
1. Germany SIEMENS INFINEON IGBT Module. ( 40-60KHZ oscillation frequency, fast response time, super high stability, almost spatter-free welding )
2. Japan Nichicon electrolytic capacitor. ( filter capacitor )
3. Imported transistor integrated block.
4. All water pipes use thermostability, High-pressure resistance best quality material.
5. Main card, signal circuit, drive circuit board, control circuit board, and components are adopted: Toshiba, Hitachi, Motorola, China's top manufacturers.
6. International advanced all-solid-state semiconductor power devices.
7. Technical advantage: perfect control, alarm display circuit, getting full automatic tracking frequency, continuously adjustable power, safe dependable protection, clear and accurate data display and etc.
8. Superiority Advantages: fast heating, wide application, small size, easy installation, simple operation, low power consumption, and high efficiency.
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:
BAR HEATING:
This type of induction heating machine is designed for the forging temperature of round and square billets section induction heating. Their modular conception makes the machine flexible and adaptable to the customer’s needs. Our power supply technology warrants a very high energy performance and allows working inside a wide range of frequencies without loss of efficiency. This heating machine consists of three sections: feeding, main equipment with generator, frame and inductor, and output section.
With a compact design, it has a main advantage:
A: The smaller necessity of space.
B: Compact design, transport of generator and machine in one piece.
C: Absence of loss in medium frequency cables.
PARTIAL HEATING
In induction heating, heat can be directly generated in one specific point which is ideal for parts with localized heating requirements. Coil designs can be optimized to heat a specific area with a desired thermal profile in a fast, efficient, and repeatable way. Partial heating machines are designed for bar end heating in forging shops. (from screws to steering racks) The machines can be configured in both manual and automatic loading system
BRASS FORGING
Induction heating systems are widely used even in non-ferrous material industries. For example, it is applied to brass forging for fittings and components molding. The starting material used in forging is presented in the form of rounded slabs, squares billet or bar materials. After heating up the material, the forming operation is done on different types of machines: mechanical impact presses, hydraulic extrusion presses, etc. The automation of forging by induction heating allows: Competitive operational costs Labor saving High productivity Minimization of start and stop times Easy adjustment, the billet temperature and cycle time can be continuously and automatically changed.
> SERVICE
Technical assistance is available any time of the day or night using our 24-hour hotline. Our experienced service team is strategically located to provide quick responses to our customers wherever they are located.
> INSTALLATION
Installation of induction equipment performed timely and accurately is critical to the financial success of a project. Our group offers complete turn-key installation service on all equipment.
> CUSTOMER SUPPORT
Replacement power units are designed to replace all makes and models. Solid State contactors are designed to replace electro-mechanical devices. Infrared imaging for locating extraordinary sources of heat in induction equipment. Pre-packaged set of tools for equipment maintenance.
> TRAINING
Our group offers professional training by certified, experienced instructors. Regularly scheduled schools combine classroom and hands-on training on power supply troubleshooting techniques and maintenance, safety procedures, testing, reading schematics, applications and the basics of induction. The schools can be taught at our training facility or on-site at customer locations. Class curriculums are customized to the customers' needs and classes are held in a computer-friendly training center designed specifically for this purpose.
