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u-shaped inductors
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Image
Published: 09 June 2014
Fig. 8 (a) Non-encircling U-shaped inductors. (b) Close-up view of carbide guides that ride on the journal. Source: Ref 2
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Image
Published: 09 June 2014
Image
in Systematic Analysis of Induction Coil Failures and Prevention
> Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 45 Comparison of a conventional U-shaped inductor (top three images), which uses carbide guides to ride on a journal required to be hardened while a crankshaft rotates during the heating cycle, compared to a SHarP-C inductor (bottom two images) that is more rigid and robust, being CNC
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Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005865
EISBN: 978-1-62708-167-2
... belong to the same group of the critical engine/powertrain components. This article focuses on induction technologies used for surface hardening and tempering of automotive crankshafts, and provides general information on U-shaped inductors with crankshaft rotation and clamshell or split inductors...
Abstract
Induction heat treatment is a common method for hardening and tempering of crankshafts, which are necessary components in almost every internal combustion engine for cars, trucks, and machinery, as well as pumps, compressors, and other devices. Similar to crankshafts, camshafts also belong to the same group of the critical engine/powertrain components. This article focuses on induction technologies used for surface hardening and tempering of automotive crankshafts, and provides general information on U-shaped inductors with crankshaft rotation and clamshell or split inductors without crankshaft rotation and their pros and cons. It also describes the effect of post-heat-treatment processes in crankshafts. The article concludes with a discussion on induction hardening of camshafts that focuses on those used in automobiles and truck engines.
Image
Published: 01 November 2010
Fig. 9 Crankshaft hardening inductors made of copper bar or tube. Comparison of U-shaped inductors (top) versus C-inductors (bottom)
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Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005842
EISBN: 978-1-62708-167-2
... parameters selection, production rate, etc.). Special inductors comprise the large family of different designs, including pancake, hairpin, split-return, butterfly, U-shaped, passive-active, clamshell, as well as inductors with doors, doorless, channel, C-core, transverse flux, traveling wave inductors...
Abstract
This article focuses on the frequently encountered causes of induction coil failures and typical failure modes in fabrication of hardening inductors, tooth-by-tooth gear-hardening inductors, clamshell inductors, contactless inductors, split-return inductors, butterfly inductors, and inductors for heating internal surfaces. It discusses the current density distribution and the skin effect, the proximity effect, and crack-propagation specifics. The article also describes selected properties of copper alloys, the electromagnetic edge effect of coil copper turn, and the effect of magnetic flux concentrators on coil life. It also reviews the importance of having appropriate and reliable electrical contacts.
Image
Published: 09 June 2014
Fig. 28 Comparison of power density distribution when applying a magnetic flux concentrator with a profiled single-turn inductor in selective heat treating. (a) Power density distribution generated by a bare coil (left) compared to coil with a U-shaped flux concentrator (right). (b) Coil
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Image
Published: 09 June 2014
Fig. 31 Results of computer simulation (using Flux2D finite element software) of induction hardening of selected areas of cup-shaped component using 2 two-turn inductors and “U”-shaped magnetic flux concentrator after 8 s of heating. Source: Ref 35
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Image
Published: 09 June 2014
Fig. 30 Selective hardening of end regions of cup-shaped component; (a) FEA mesh and (b) computer-simulated magnetic field distribution at the final stage of heating using 2 two-turn inductors and “U”-shaped magnetic flux concentrators. Only the right half of the component is shown due to its
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Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005841
EISBN: 978-1-62708-167-2
... the efficiency of the hairpin inductors. If the two legs of the hairpin coil are close to each other, the proximity effect will cause much of the current in the two legs to flow on the inside surfaces of the coil legs facing each other. Application of U-shaped flux concentrators around the coil legs...
Abstract
Inductors used for brazing can be machined from solid copper shapes or fabricated out of copper tubing, depending on the size and complexity of the braze joint geometry to be heated. This article provides information on inductors (coils) that are generally classified as solenoid, channel (slot), pancake, hairpin, butterfly, split-return, or internal coils. It discusses the variables pertinent to the design of inductors for brazing, soldering, or heat treating. The article presents various considerations for designing inductors for brazing of dissimilar materials that present a unique challenge in the field of induction brazing.
Image
Published: 09 June 2014
Fig. 23 Magnetic field distribution (a) without and (b) with a U-shaped magnetic flux concentrator located around the central leg of a split-return inductor. Source: Ref 19
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Image
Published: 01 November 2010
Fig. 17 Magnetic field distribution without (left) and with (right) a U-shaped magnetic flux concentrator located around the central leg of a split-return inductor. Source: Ref 42
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Image
in Systematic Analysis of Induction Coil Failures and Prevention
> Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 54 Magnetic field distribution without (left) and with (right) a U-shaped magnetic flux concentrator located around the central leg of a split-return inductor (results of computer modeling). Source: Ref 36
More
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005839
EISBN: 978-1-62708-167-2
... with U-shaped inductors ( Fig. 23 ). The distance from the output of the transformer to the heating area of the coil must be relatively long to ensure that the counterweights of the crankshaft will not hit the transformer. This is a challenge, because in this style of coil the electrodynamic forces...
Abstract
This article provides information on single-shot and scanning, the two types of induction heat treating processes that are based on whether the induction coil is moving relative to the part during the heating process. It describes the effect of the frequency of induction heating current on the induction coil and process design, and the control of heating in different areas of the inductor part. The article reviews three main tools for adjustment of coil design and fabrication: coupling gap, coil copper profile, and magnetic flux controllers. It examines the method of holding a part and presenting it to the inductor during the initial inductor design. The article provides information on coil leads/busswork and contacts that mechanically and electrically connect the induction coil head to the power supply. It concludes with a discussion on flux and oxide removal, leak and flow checking, silver plating, and electrical parameter measurement.
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005902
EISBN: 978-1-62708-167-2
... of an inductor runout. Copper or nonmagnetic steel is the material used for the cooling jacket. Structural Shapes Depending on the application, the channel inductors are executed in a single- or twin-loop design. The single-loop model ( Fig. 12 ) is deployed primarily for holding and pouring cast iron...
Abstract
An induction channel furnace consists of a tiltable furnace vessel with refractory lining onto which an inductor or several inductors are flange mounted. This article includes a discussion on the design for holding and dosed-pouring of the iron melts, design for melting the materials, and refractory lining of furnace vessel. It provides information on the structural changes and refractory lining of channel inductors. The article also includes a discussion on power supplies deployed in channel inductor furnaces: line-frequency power supply for melting iron, and converter power supply for melting nonferrous metals. It concludes with an overview of the inductor cooling circuit.
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005892
EISBN: 978-1-62708-167-2
... algorithms and multiobjective evolutionary strategy algorithms associated with evolutionary computing. The article provides information on field-based optimization problems. It also discusses the design of the pancake inductor that implies the solution of coupled electromagnetic and thermal fields, along...
Abstract
Optimization plays a key role in the design of any structure or system, and electromagnetic devices are no exception. This article provides a description of the formulation of a design problem, and provides a review of the Paretian optimality. It focuses on nondominating sorting algorithms and multiobjective evolutionary strategy algorithms associated with evolutionary computing. The article provides information on field-based optimization problems. It also discusses the design of the pancake inductor that implies the solution of coupled electromagnetic and thermal fields, along with the use of optimal design procedures, to identify the best possible device or process.
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005891
EISBN: 978-1-62708-167-2
... mesh, and Fig. 1 ( b – e ) show the sequential dynamics of induction heating of a selected area of a steel rail prior to a sizing operation applying two two-turn butterfly inductors positioned on each side of the rail. Properly positioned, two U-shaped lamination stacks help to increase coil...
Abstract
Induction heating has the ability to concentrate the electromagnetic field and heat within a certain area of the workpiece. This article provides a detailed discussion on the end heating of bars, rods, and billets using solenoid inductors, oval inductors, and channel inductors. It reviews the importance of computer modeling in predicting the impact of different, interrelated, and nonlinear factors on the transitional and final thermal conditions of billets and bars. The article describes the most appropriate processes to improve end heating process effectiveness. Induction bending of narrow circumferential band of pipe or tube is also discussed. The article concludes with a discussion on stress relieving of pipe ends and welded areas.
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005893
EISBN: 978-1-62708-167-2
.... The maximum allowable value of inductor voltage U ( t ) (considered as lumped control input) is always restricted by maximum value U max (known a priori) defined by power supply limitations. The minimum value is always equal to zero (the power supply is switched off). Thus, it is reasonable to select...
Abstract
This article describes the effects of furnace atmospheric elements, including air, water vapor, molecular nitrogen, carbon dioxide, and carbon monoxide, on steels. It provides useful information on six groups of commercially important prepared atmospheres classified by the American Gas Association on the basis of the method of preparation or on the original constituents employed. These groups are designated and defined as follows: Class 100, exothermic base; Class 200, prepared nitrogen base; Class 300, endothermic base; Class 400, charcoal base; Class 500, exothermic-endothermic base; and Class 600, ammonia base. These are subclassified and numerically designated to indicate variations in the method by which they are prepared. The article also contains a table that lists significant furnace atmospheres and typical applications.
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005897
EISBN: 978-1-62708-167-2
... Abstract Estimation of process parameters for selective heating and heat treating of simple- and complex-shaped workpieces in induction hardening can be accurately carried out using numerical simulation techniques such as the finite-element analysis and the finite-different method. Along...
Abstract
Estimation of process parameters for selective heating and heat treating of simple- and complex-shaped workpieces in induction hardening can be accurately carried out using numerical simulation techniques such as the finite-element analysis and the finite-different method. Along with the significant benefits of modern numerical simulations, it is important to be able to use rough estimation techniques to develop a general understanding of the critical parameters of a particular induction heating system. This article discusses such numerical techniques for estimating the critical parameters: workpiece power estimation; estimation of electrical and thermal efficiency of the coil; and frequency selection for heating solid cylinders, tubes, pipes, slabs, plates, strips, and rectangular workpieces.
Series: ASM Handbook
Volume: 22B
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.hb.v22b.a0005533
EISBN: 978-1-62708-197-9
... through it, leading to an increase in current-carrying area, reduced coil resistance and coil losses, and increased overall electrical efficiency. Fig. 9 Crankshaft hardening inductors made of copper bar or tube. Comparison of U-shaped inductors (top) versus C-inductors (bottom) As discussed...
Abstract
This article describes the applications of induction heat treatment of metals, including normalizing, annealing, hardening, and tempering and stress relieving. It discusses the simulation techniques of the electromagnetic and thermal processes that occur during induction heat treating. The article explains the finite-difference method, finite-element method, mutual impedance method, and boundary-element method for the numerical computation of the induction heat treating processes. It also discusses the direct and indirect coupling approaches for coupling the electromagnetic and heat-transfer problems. Modern computer simulation techniques are capable of effectively simulating electromagnetic and thermal phenomena for many processes that involve electromagnetic induction. The article considers the challenges faced by developers of modern simulation software.
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