Crankshaft Coil Engineering, Design, and Computer Simulation

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http://fluxtrol.com An Overview of Crankshaft Coil Engineering, Design, and Computer Simulation Services offered by Fluxtrol.

Fluxtrol

Crankshaft Coil Engineering,
Design, and Computer Simulation

Fluxtrol.com 1-248-393-2000

Induction Diesel Crankshaft Coil Design

Fluxtrol Concentrators on Diesel
Crankshaft Coils are Easy to Assemble,
Result in Long Tooling Life and Create a Quality Hardened Pattern

Fluxtrol.com 1-248-393-2000

Induction Crankshaft Coil Design

Fluxtrol’s Robust Induction
Crankshaft Coils Designs
Have Long Life and
Produce Great Parts

Fluxtrol.com 1-248-393-2000

One Piece Machined Induction Crankshaft Head
Results in Longer Fatigue Cycle Life

Fluxtrol.com 1-248-393-2000

One Piece Machined Induction Crankshaft Head
Designs Result in Longer Fatigue Cycle Life

Fluxtrol.com 1-248-393-2000

Concentrator Replaces Laminations on
Induction Crankshaft Coil

Fluxtrol.com 1-248-393-2000

Induction Crankshaft Radius Pattern

Fluxtrol.com 1-248-393-2000

Induction Hardened Radius Pattern on
Diesel Crankshaft

Fluxtrol.com 1-248-393-2000

Crankshaft Induction Hardened Radius Pattern

Fluxtrol.com 1-248-393-2000

Heavy Duty
Induction
Crankshaft
Bearing Coil

Fluxtrol.com 1-248-393-2000

Robust
Crankshaft
Coil Design

Fluxtrol.com 1-248-393-2000

Induction Crankshaft Bearing Coil

Fluxtrol.com 1-248-393-2000

Induction Crankshaft Coil Head with Concentrators

Fluxtrol.com 1-248-393-2000

Concentrators on Induction Crankshaft Coil

Fluxtrol.com 1-248-393-2000

Induction Automotive Crankshaft Coil

Fluxtrol.com 1-248-393-2000

One Piece Induction Crankshaft Coil Head

Fluxtrol.com 1-248-393-2000

Induction
Crankshaft
Coils Designed
by Fluxtrol

Fluxtrol.com 1-248-393-2000

Computer Simulation Modeling of
Induction Coil for Crankshaft

Fluxtrol.com 1-248-393-2000

Magnetic Flux
Controllers on
Induction
Crankshaft
Coils

Fluxtrol.com 1-248-393-2000

One Piece = Longer Life
Induction Crankshaft Coil Heads

Fluxtrol.com 1-248-393-2000

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With the use of good design practices, one can improve coil longevity and improve production quality. By eliminating failure points in the initial design, proper material selection, improved cooling and proper magnetic flux control, induction tooling life can be increased. Computer simulation has been proven to be an effective tool for predicting not only electromagnetic parameters of a designed system, but also heat patterns in a given part and in the induction coil itself. When a coil has magnetic flux controllers present, their influence may also be predicted by computer simulation. With an extensive library of published case studies in induction coil design and performance evaluations, we are confident with the use of these tools and proper coil geometries and implementation, production life and quality can be improved on most induction heat treating inductors. These design practices have been used by the authors for over 20 years with proven results. A case is examined of a CVJ stem hardening coil, in which the principles discussed can be applied to most other hardening coils.

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Bimaterial products can be hot forged from a bimaterial billet where the steel shell encloses the lightweight core fully. A bimaterial billet can be forged in solid state however a better forging quality can be achieved if the core material is viscous thereby providing uniform hydrostatic pressure to steel shell during forging similar to a hydroforming process. However, the similarity only pertains to the hydrostatic pressure developed inside the deforming billet not to the process temperatures. While hydroforming is done at room temperatures the hot hydroforging is done at temperatures greater than 1000C enabling deformation of steel into intricate topologies without a fracture. Other differences between the hydroforming and hot hydroforging are that the amount of fluid is constant in hot hydroforging and the fluid may solidify and become an integral part of the product after forging and cooling. The lightweight core material will need to have a lower melting or softening temperature than the steel for Hot Hydroforging. Aluminum, magnesium, and glass are such candidate lightweight materials.

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By Dr. Valentin Nemkov - Fluxtrol Inc. Magnetic flux controllers are widely used in induction heating systems for concentration, shielding or redistribution of the magnetic field which generates power in the part to be heated. Controllers, made of Soft Magnetic Composites (SMC), provide accurate heat pattern control, improve parameters of inductors and performance of the entire installation. In melting systems, especially in the case of vacuum furnaces, cold crucible and other specialty furnaces, the magnetic control can provide large energy savings, magnetic field shielding, shorter melting cycles and optimized field distribution for enhancement of the metallurgical processes. Due to the diversity of applications, service conditions of controllers are very different including very severe cases. Mechanical, magnetic, electrical, thermal and other properties must be considered in design and application of SMC. This article describes properties and performance of SMC typically used in induction heating technology. Several presented case stories are based on more than 20 years of R&D and practical experience of scientists and practitioners at Fluxtrol, Inc. Presented material may be interesting not only for induction heating community but also for all people using AC magnetic fields in technological processes.

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Characteristics of Induction heating Carbon Fiber-Reinforced Thermoplastic (CFRT): -Electrical Resistivity Determination of two specific CFRT’s -Direction-specific by four-point method -Equivalent resistivity by impedance method -Thermal behavior of the studied materials -Electromagnetic computer simulation of induction heating a lap joint. -Different coil designs examined -Current flow with resistivity differences examined

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MAGNETIC FLUX CONTROLLERS are materials other than the copper coil that are used in induction systems to alter the flow of the magnetic field. Magnetic flux controllers used in power supplying components are not considered in this article. Magnetic flux controllers have been in existence since the development of the induction technique. Michael Faraday used two coils of wire wrapped around an iron core in his experiments that led to Faraday’s lawof electromagnetic induction, which states that the electromotive force (emf) induced in a circuit is directly proportional to the time rate of change of the magnetic flux through the circuit. After the development of the induction principle, magnetic flux controllers, in the form of stacks of laminated steel, found widespread use in the development of transformers for more efficient transmission of energy (Ref 1, 2). Magnetic cores gained widespread use in the transformer industry because they increased the amount of magnetic flux produced with the same alternating current. The higher the magnetic flux, the higher the emf, which results in an increase in energy transfer efficiency from the primary winding to the secondary winding. Similar to transformers, magnetic cores were used on early furnaces for induction melting (Ref 1, 2). The benefits of magnetic flux controllers vary depending on the application. For induction heating, magnetic flux controllers can provide favorable and unfavorable paths for magnetic flux to flow, resulting in increased heating in desired areas and reduced the heating in undesirable areas, respectively.Magnetic flux controllers are not used in every induction heating application, but their use has increased (Ref 3, 4). Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.

Magnetic Flux Controllers in Induction Heating and Melting by Robert Goldstei...

Fluxtrol Inc.

FOR INDUCTION MELTING AND MASS HEATING, the early induction heating coils were manufactured from copper tubing wrapped in multiple turns around a mandrel. The first induction heat treating coils were developed for crankshaft hardening in the 1930s (Fig. 1, 2) (Ref 1–4). Unlike the melting and mass heating coils, the heat treating induction coils were machined. These inductors consisted of two parts with a hinge on one side that would open and shut around the crankshaft journal. Quench holes were drilled on the inner diameter of the induction coil to deliver quench to the part afterheating. This pioneering development was the culmination of many years of hard work by a large team and clearly demonstrated the different requirements for induction heat treating as compared to melting and mass heating. Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited. Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.

Design and Fabrication of Inductors for Induction Heat Treating

Fluxtrol Inc.

In recent years, there has been a significant increase in the customer demands for improved induction coil lifetime. This has led to several publications in recent years by induction tooling manufacturers [1-4]. The main conclusion in these papers is that besides mechanical crashes the cause of most induction coil failures is localized overheating of the coil copper due to insufficient cooling. What is lacking from these publications is any way to determine what is sufficient cooling. In this paper, a scientific method for determining local copper temperatures will be presented. This will include evaluations of heat transfer coefficients for different sections of a multi-component inductor, dependence of heat transfer coefficient on water pressure and water passage cross-section, non-uniform power density distributions in various 2-D cross-sections and the resulting temperature distribution in the copper winding. The effects of duty cycle on optimal design will also be considered.

Increasing Inductor Lifetime by Predicting Coil Copper Temperatures Paper

Fluxtrol Inc.

Increasing Inductor Lifetime by Predicting Coil Copper Temperatures Presentation

Fluxtrol Inc.

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Fluxtrol Inc.

Specification and Use of a Flux Concentrator

Fluxtrol Inc.

http://fluxtrol.com In induction hardening, thermal fatigue is one of the main failure modes of induction heating coils. There have been papers published that describe this failure mode and others that describe some good design practices [1-3]. The variables previously identified as the sources of thermal fatigue include radiation from the part surface, frequency, current, concentrator losses, water pressure and coil wall thickness. However, there is very little quantitative data on the factors that influence thermal fatigue in induction coils available in the public domain. By using finite element analysis software this study analyzes the effect of common design variables of inductor cooling, and quantifies the relative importance of these variables. A comprehensive case study for a single shot induction coil with Fluxtrol A concentrator applied is used for the analysis.

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Fluxtrol Inc.

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