Contents

1 Theoretical Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Induction Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Direct Resistance Heating . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Basic Electromagnetic Phenomena . . . . . . . . . . . . . . . . . . . . 3
1.4.1 Maxwell Equations . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4.2 Theorem and Poynting’s Vector . . . . . . . . . . . . . . . . 5
1.4.3 Phenomena Affecting the Current Density
Distribution in Conductors . . . . . . . . . . . ......... 8
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 22

2 Electromagnetic Field in Workpieces with Flat Surfaces . . . . . . . . 23

2.1 Semi-infinite Body of Homogeneous Material . . . . . . . . . . . . 23
2.1.1 Induction Heating . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1.2 Resistance Heating . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Semi-infinite Body of Ferromagnetic Material . . . . . . . . . . . . 40
2.3 Infinite Metal Slab of Homogeneous Material. . . . . . . . . . . . . 51
2.3.1 Induction Heating by a Flat Inductor on One Side
of the Workpiece . . . . . . . . . . . . . . . . . . . . . . . ... 51
2.3.2 Metal Slab in Longitudinal Flux Inductor
(Exciting Magnetic Field on Both Sides
of the Workpiece) . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3.3 Direct Resistance Heating . . . . . . . . . . . . . . . . . . . . 65
2.4 Slab of Rectangular Cross-Section . . . . . . . . . . . . . . . . . . . . 71
2.4.1 Induction Heating . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4.2 Energy in Slabs of Rectangular Cross-Section . . . . . . 76
2.4.3 Direct Resistance Heating . . . . . . . . . . . . . . . . . . . . 80
2.5 Slab of Magnetic Material . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.5.1 Induction Heating . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.5.2 Resistance Heating . . . . . . . . . . . . . . . . . . . . . . . . . 83
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

vii
viii Contents

3 Electromagnetic Field in Cylindrical Bodies . . . . . . . . . . . . . . . . . 85

3.1 Solid Cylindrical Workpieces of Homogeneous Material . . . . . 85
3.1.1 Induction Heating of Cylindrical Workpieces . . . . . . . 86
3.1.2 Direct Resistance Heating . . . . . . . . . . . . . . . . . . . . 93
3.2 Solid Cylindrical Workpieces of Ferromagnetic Material . . . . . 100
3.2.1 Direct Resistance Heating . . . . . . . . . . . . . . . . . . . . 100
3.2.2 Induction Heating Solid Ferromagnetic Cylinder . . . . . 105
3.3 Hollow Cylindrical Workpieces of Homogeneous Material . . . . 107
3.3.1 Induction Heating with Internal and External
Exciting Magnetic Field. . . . . . . . . . . . . . . . . . . . . . 107
3.3.2 Induction Heating with External Exciting
Magnetic Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.3.3 Induction Heating of Hollow Cylindrical Workpieces
with Internal Inductors. . . . . . . . . . . . . . . . . . . . . . . 114
3.3.4 Resistance Heating of Cylindrical Hollow
Workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.4 Hollow Cylindrical Workpieces of Ferromagnetic Material. . . . 120
3.4.1 Induction Heating . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.4.2 Resistance Heating . . . . . . . . . . . . . . . . . . . . . . . . . 122
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4 Special Problems in Induction and Resistance Heating . . . . . . ... 127

4.1 Resistance Heating of Ferromagnetic Workpieces
of Rectangular Cross-section . . . . . . . . . . . . . . . . . . . . . ... 127
4.1.1 Influence of Power Supply Circuit on Heating
Transient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 134
4.2 Curved Conductors with Cylindrical Cross-Section . . . . . . ... 140
4.2.1 Electromagnetic Processes in Toroidal Conductors
of Circular Cross-section . . . . . . . . . . . . . . . . . . ... 140
4.2.2 Resistance Heating of Curved Cylindrical
Work-Pieces. . . . . . . . . . . . . . . . . . . . . . . . . . . ... 149
4.2.3 Equalization of Temperature Distribution
in the Cross-section of Bent Conductors . . . . . . . . . . 153
4.3 Transverse Flux Induction Heating . . . . . . . . . . . . . . . . . . . . 164
4.3.1 Preliminary Choice of Design Parameters. . . . . . . . . . 172
4.3.2 Final TFH System Characteristics . . . . . . . . . . . . . . . 177
4.3.3 Calculations of Heating Transients . . . . . . . . . . . . . . 179
4.3.4 Other Inductor Geometries . . . . . . . . . . . . . . . . . . . . 182
4.3.5 Recent Developments and Conclusions . . . . . . . . . . . 186
4.4 Planar Circular Coils for Induction Heating . . . . . . . . . . . . . . 191
4.4.1 Analytical Solutions . . . . . . . . . . . . . . . . . . . . . . . . 191
4.4.2 Examples of Results Obtained with the Analytical
Solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 196
4.4.3 Examples of Numerical Results . . . . . . . . . . . . . ... 197
Contents ix

4.5 Induction Heating of “Long” Cylindrical Workpieces

with Inductors of Finite Axial Length . . . . . . . . . . . . . . . . . . 200
4.6 Pulse Induction Hardening of Complex Workpieces . . . . . . . . 214
4.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.6.2 Single-Frequency Processes . . . . . . . . . . . . . . . . . . . 215
4.6.3 Dual-Frequency Processes . . . . . . . . . . . . . . . . . . . . 220
4.6.4 Gear Spin Hardening: Main Factors Influencing
the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.6.5 Numerical Simulations and Results . . . . . . . . . . . . . . 230
4.6.6 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.7 Induction Heating of Cylindrical Billets Rotating in DC
Magnetic Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.7.2 Electromagnetic Solution for the Infinitely Long
Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.7.3 Heating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.7.4 Edge Effect in Finite Length Billet . . . . . . . . . . . . . . 250
4.7.5 Influence of Shape and Position of Superconducting
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.7.6 Optimisation of the Heating Process . . . . . . . . . . . . . 256
4.8 Induction Heating with Permanent Magnets . . . . . . . . . . . . . . 258
4.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.8.2 FEM Solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
4.8.3 Analytical Solution . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.8.4 Calculation, Experimental Results and Design
Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.9 Inductors for Induction Heating of Internal Cylindrical
Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.9.1 Inductor Equivalent Resistance . . . . . . . . . . . . . . . . . 269
4.9.2 Results of Numerical Analysis . . . . . . . . . . . . . . . . . 270
4.9.3 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.10 Electromagnetic Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.10.2 Evaluation by Lorentz’s Law of Forces
in “Long” Cylindrical Systems . . . . . . . . . . . . . . . . . 276
4.10.3 Forces in the Induction Heating of Disk Plates
with Planar Circular Coils . . . . . . . . . . . . . . . . . . . . 284
4.10.4 Evaluation of Forces by Variation
of the Field Energy . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.10.5 Forces in Induction Heating of the Ends
of Non-magnetic Bars . . . . . . . . . . . . . . . . . . . . . . . 290
4.10.6 Forces in Induction Heating of the Ends
of Magnetic Bars . . . . . . . . . . . . . . . . . . . . . . . . . . 293
4.10.7 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
x Contents

5 Analytical and Numerical Methods for Calculation

of Induction and Conduction Heating Systems . . . . . . . . . . . . . . . 303
5.1 Calculation of Induction Heating Systems with the Equivalent
Magnetic Circuit Method . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
5.2 Calculation of Induction Heating System with Analytical
Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
5.3 1D Finite Difference Numerical Solution for Induction
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
5.3.1 Electromagnetic Problem Solution. . . . . . . . . . . . . . . 313
5.3.2 Solution of Thermal Problem . . . . . . . . . . . . . . . . . . 315
5.4 Commercial 1D Code ELTA for Induction Heating . . . . . . . . . 317
5.4.1 Case Study 1: Through Heating of Non-magnetic
Steel Billets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
5.4.2 Case Study 2: Through Heating of Magnetic
Steel Billets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
5.5 VIM: Volume Integral Method of the Mutually
Coupled Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
5.6 Calculation of Parameters of Direct Resistance
Heating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
5.7 1D Finite Difference Numerical Model for DRH. . . . . . . . . . . 341
5.7.1 Electromagnetic Problem . . . . . . . . . . . . . . . . . . . . . 342
5.7.2 Examples of Coupled Numerical Solutions. . . . . . . . . 344
5.8 FEM: Finite Element Method . . . . . . . . . . . . . . . . . . . . . . . . 349
5.8.1 Preprocessor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
5.8.2 Solver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
5.8.3 Post Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
http://www.springer.com/978-3-319-03478-2