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Modelling induction heating


In many manufacturing industries, modelling induction heating process can play a big role. It brings confidence to the development engineers, regarding the design and operational parameters they must choose for each process.
Multiphysics simulation tools fit very well to run these models which couple electromagnetics, heat transfer and structural mechanics phenomena.

Objectives from modelling induction heating

One of industrial applications of induction heating is shrink-fitting of two parts. This process allows to transfer torque between the two parts for many configurations and with great robustness.

In this case it becomes crucial to know what power must be generated by the inductors.
Not enough power would mean the heated part would not deform and fit to the other part.
Too much power would mean the process consumes too much energy to assemble the parts.

Results from simulation and information extracted

The induced current in the part will dissipate heat, and this heated part will then expand. When its diameter becomes large enough, the operator can process to shrink-fit the part with the shaft. One can cut electrical power in the inductors while the part cools back to ambient temperature.

The multiphysics simulation of electromagnetics, heat transfer and structural mechanics helps to choose the right power and amount of time. These two operational parameters vary for the heating cycle and the diffusion cycle.

The industrial inductors work the same way as an induction hob in cooking appliances, with same physical principles.

Electromagnetic field of modelled inductive heating

The image shows magnetic field created by coils (blue streamlines) and the induced current in the heated part. With colours from green for no current to red for the highest current, just under the coils.
Parts are cut in a 90° sector for better visualisation.

Thermal expansion in the part during shrink-fit by induction

The animation shows the temperature variation against time on the deformed part.
Maximum temperature corresponds to light yellow colour and the real deformation is scaled in order to see its shape.

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Our simulation expertise can help companies from industries such as Medtech (health), audio, sensors, energy and environment but also research labs that would need powerful simulation hardware and software. Contact us to learn more.

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