The purpose of metal heating is to improve metal plasticity and reduce deformation resistance, so as to facilitate metal plastic deformation and obtain a good post-forging metallographic structure. Therefore, metal heating plays an important role in warm and hot forging and is an indispensable and important process. For the heating and heat treatment of metals, the most commonly used equipment at present is the medium frequency induction heating machine, which has very good results.

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Induction heating uses electromagnetic induction heating to directly heat metal blanks. Put the metal blank into a spiral coil (induction coil) that passes alternating current. The coil generates an induced electromotive force and forms a strong eddy current on the surface of the blank, which converts the electrical energy inside the blank directly into thermal energy to heat the blank.

The advantages of using a medium frequency induction heating machine for heating are fast heating speed (1.7cm/min-2.5cm/min) and a total efficiency of 50%-60%. During induction heating, the air around the blank does not flow strongly and there is less oxidation and decarburization. , good heating quality, no pollution to the environment, easy temperature control, little metal burning loss, general burning loss rate is about 0.5%, simple operation, stable work, easy to implement mechanization and automation. However, there are strict restrictions on the shape and specifications of the billet, so it is generally necessary to equip a high-temperature box-type resistance furnace or a flame-heated box-type furnace to heat the forgings that need to be repaired.

Medium frequency induction heating machines are usually composed of power supply, inductor, capacitor bank, contactor and electric control device. The actual unit electric energy consumption during heating is (0.4-0.5) kwh/kg (low alloy structural steel heating temperature 1200℃-1250℃ ).

What is the difference between high frequency and low frequency induction heating?

The difference between high frequency and low frequency induction heating lies in the operating frequency and the depth of penetration.

High frequency induction heating machines typically operate at frequencies between 60 kHz to 200 kHz. At these frequencies, the current penetration depth is relatively shallow, usually less than 2 mm. High frequency induction heating is suitable for applications such as brazing, hot forging of small-sized materials (typically round bars below 15 mm), and quenching operations with a layer depth of about 1-2 mm.

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On the other hand, low frequency induction heating machines, also known as medium frequency induction heating machines, operate at frequencies between 500 Hz to 10,000 Hz. The current penetration depth at these frequencies is deeper, ranging from 2 to 10 mm. Low frequency induction heating is commonly used for parts that require a deeper hardening layer, such as medium-modulus gears, large-modulus gears, and shafts with larger diameters.

The choice between high frequency and low frequency induction heating depends on various factors, including the customer's purchase cost, workpiece material, and process requirements. For certain workpieces, low-power high-frequency equipment and higher-power ultra-audio equipment may produce similar heating effects.

It's important to note that the relationship between the frequency of alternating current (AC) and the depth of heat penetration is inversely proportional. Higher frequencies result in shallower heating, while lower frequencies allow for deeper penetration. Frequencies between 100 to 400 kHz are ideal for quickly heating the surface or skin of small or larger parts, while lower frequencies between 5 and 30 kHz are more effective for deep, penetrating heat.

The choice of frequency also depends on the electrical resistivity of the material being heated. Metals with high electrical resistivity, such as steel, carbon, tin, and tungsten, heat up quickly due to their strong resistance to electric current. Metals with low resistivity, like copper, brass, and aluminum, take longer to heat up. Resistivity increases with temperature, meaning hot steel sheets are more susceptible to induction heating than cold steel sheets.

In terms of induction melting furnaces, the frequency range typically used is between 50 to 400 kHz. However, the frequency can go even higher depending on factors such as melting speed, material type, and furnace volume. Higher frequencies result in higher penetration into the metal, referred to as skin depth.

Using an induction melting furnace offers advantages such as less heat loss compared to traditional heating equipment. Induction furnaces utilize induction heating, which heats the metal directly, reducing heat loss through conduction. This results in higher thermal efficiency and energy savings.

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