Induction Heating System for Forging

Induction Heating Machine For Forging by TY INDUCTION

At TY INDUCTION,we take pride in delivering cutting-edge induction heating solutions that redefine efficiency and precision in the forging industry. With over 15 years of global expertise, we have consistently provided industrial induction heating equipment and customer-centric solutions. Our systems are designed to cater to a diverse range of applications, offering superior performance in multiple industries. The main products offered by TY include the Billet/Bar Induction Total Heating Equipment and the Billet/Bar Induction Partial Heating Machine. These advanced systems are designed to provide efficient and precise heating solutions for various forging applications, catering to the specific needs of the industry. With TY's cutting-edge technology and reliable performance, customers can expect superior results and increased productivity in their forging processes.

Innovative Technology of TY Forging Induction Heating Machine with Excellent Performance
The TY Induction Forge Heating Technology offers a comprehensive solution for heating a diverse range of bar and billet diameters. Equipped with fully automatic or semi-automatic material handling systems, water cooling systems, and temperature controls, it ensures efficient and precise heating processes. TY's induction power supply utilizes advanced IGBT technology and LC series resonant circuits, ensuring reliable performance even under varying load conditions. With the capability to start at 100% capacity and run continuously for 24 hours, it provides uninterrupted operation for demanding forging applications. Additionally, self-diagnostic features such as fault LEDs and alarm indicators contribute to the system's reliability and ease of maintenance. This innovative forging induction heating machine by TY is specifically designed to meet the rigorous demands of the forging industry, providing unparalleled efficiency and performance.

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Industries We Serve

1. Forging Companies

Usage: TY INDUCTION's induction heating systems play a pivotal role in the initial stages of the forging process. We excel in heating metal workpieces to the precise temperature required for shaping and forming.

Application: From billets to bars, our systems are adept at heating raw materials before forging, ensuring the achievement of the desired shape and properties.

2. Manufacturing Companies

Usage: In the production of specific metal components requiring forging, TY INDUCTION's induction heating systems are seamlessly integrated into manufacturing lines.

Application: Our systems heat specific parts or materials, facilitating further processing and assembly with unmatched precision.

3. Automotive Industry

Usage: Precision and strength are paramount in the automotive sector, and our induction heating is instrumental in crafting critical components.

Application: Engine components, gears, and other crucial parts undergo induction heating for forging to meet the mechanical properties essential for durability.

4. Aerospace Industry

Usage: Aerospace demands lightweight yet high-strength components, and TY INDUCTION meets this challenge through induction heating systems.

Application: Landing gear parts, turbine blades, and structural elements undergo our forging process, meeting stringent aerospace standards.

5. Heavy Machinery Manufacturers

Usage: Induction heating systems from TY INDUCTION contribute to the production of durable and robust components for heavy machinery.

Application: Gears, shafts, and structural components undergo our forging process, ensuring they withstand the rigors of heavy-duty operations.

6. Oil and Gas Industry

Usage: Corrosion-resistant components are critical in the oil and gas sector, and our induction heating systems excel in creating such components.

Application: Drill bits, valves, and other critical components used in exploration and extraction undergo induction heating for forging.

7. Construction Industry

Usage: TY INDUCTION's induction heating systems are utilized in the construction industry to produce components with the required strength and durability.

Application: Crane parts, structural elements, and earthmoving equipment components are forged using our advanced induction heating technology.

8. General Engineering Companies

Usage: Our systems cater to the diverse needs of general engineering firms, providing solutions for a wide range of forged components.

Application: From small precision components to larger structural elements, TY INDUCTION's induction heating systems adapt to various engineering requirements.

TY INDUCTION's Strengths:

1. Comprehensive Solutions: We provide turnkey and fully automatic induction heating systems that cover Heat Treatment, Forging/Forming, Shrink Fitting, Bending/Expanding/Extrusion/Coating of pipes and tubes, Brazing, and Melting.

2. Flexibility and Longevity: Our induction heating machines offer flexibility, long life, and advanced technology, ensuring adaptability to different processes and prolonged system life.

3. Customization and Integration: Our engineers specialize in developing custom induction heating equipment, OEM solutions, or complete turnkey systems. Our systems can seamlessly integrate into both manual assembly processes and fully automated production lines.

4. Innovation: TY INDUCTION's breakthrough technology in induction power supplies design stands as a testament to our commitment to innovation and advancement in the field.

5.Experienced Team: Our team of experts, including electrical engineers, mechanical engineers, automation engineers, metallurgists, and application specialists, is ready to collaborate with you throughout the system life cycle.

Choose TY INDUCTIONfor induction heating systems that redefine the standards of efficiency, precision, and durability across diverse industries.Partner with us for forging solutions that surpass expectations!

What is induction forging?

Induction forging uses induction heating of metal parts before they are formed or "deformed" by presses or hammers.

What are the advantages of induction forging?

Induction forging has several key advantages over furnace forging. The speed and controllability of induction heating ensures high throughput. Induction minimizes oxidation and helps maintain metallurgical integrity. Induction also saves energy because it provides precise localized heat. The consistency and repeatability of induction makes it ideal for integration into automated production lines.

Where is induction forging used?

Induction forging is widely used in the metal and foundry industries to heat billets, bars and bar ends. Metals typically forged with TY Induction systems include aluminum, brass, copper, steel and stainless steel.

What is hardening?

Hardening can simply be defined as any process that increases the hardness and decreases the ductility of a material. The purpose of this is to strengthen high wear surfaces and extend the life of the part. Although there are many different methods of hardening that may or may not be more suitable depending on the material used, induction techniques are often used for the hardening process known as hardening and tempering.

What is Quenching & Tempering?

Quenching and Tempering is a hardening process that can only be performed in medium to high carbon steel. The steel is heated to a high enough temperature for the crystal structure of the iron to change from ferrite to austenite. In this altered crystal state, the steel is able to dissolve much more carbon than it otherwise could. The steel is then quenched using water, oil, or, in the case of induction equipment, a water-polymer solution. This quenching cools the steel rapidly which prevents carbon precipitates from forming which can reduce the final hardness of the steel. Once the steel cools to a low enough temperature, the crystal structure tries to return to its low-temperature state. At this point, the steel has dissolved more carbon than it can hold in its original low-temperature state so it transforms into a different crystal structure called martensite. Martensite is extremely hard due to having distorted crystal structures and a higher saturation of carbon. At this point, the steel is very hard but as a result, it is also very brittle. Tempering involves heating the steel back up to a much lower temperature in order to slightly reduce the hardness and, in turn, reduce the brittleness. The temperature at which the steel is heated depends on how much hardness needs to be retained by the steel. Once the desired hardness is achieved, the steel is quenched again in order to prevent residual heat from tempering the steel further.

Quenching & Tempering with Induction

Induction technology is most often used in Quenching and Tempering procedures where it provides the most distinct advantages. This procedure requires extreme amounts of precision in both the heating and quenching of the steel in order to achieve the desired hardness profile. Even extremely small variations in the procedure such as heating for a second too long or quenching at the wrong temperature can result in large variations from part to part. Because of this, precise control of the process becomes paramount. Induction technology offers more control than any other method of heating.

Automatic handling and fixturing of components for heating and quenching provides for high production rates and helps to produce consistent results part after part. Induction is by far the fastest method of hardening and heat treating. As a result, the process produces minimal distortion, no surface decarburization, fine grain microstructure, and precisely controlled hardness patterns. induction is the perfect solution for any facility looking to step up production to the next level.

Induction Case Hardening

Selective induction case hardening can enhance the performance of parts by providing hybrid mechanical properties, hardness where needed on wear surfaces, and ductility in the core to provide impact resistance.

Selective induction hardening has the ability to specifically target and apply heat rapidly to a localized area of a part. As a result, the part develops a layer, or case, of hardened material. This is ideal for parts that are highly stressed in operation and require a combination of mechanical properties. For example, high yield strength, fatigue resistance, and resistance to wear at the same time.

The precise hardness pattern can be controlled by appropriate adjustment of the frequency used, induction coil geometry, power level, and the location of the part in the coil. The hardness pattern remains highly consistent from part to part due to industry-leading precision in Radyne systems. Rotation during heating assures a uniform case.

Progressive Induction Hardening| Induction Scanning

Often, parts need to be surface hardened in selected areas to provide optimum performance and long-term service life. Induction hardening uses progressive heating and quenching, providing an economical method for machining shafts or other parts.

By gradually passing the steel shaft through the heating coil into the water quenching unit, the outer skin can be heated, quenched and hardened without affecting its core. When complete uniformity is desired, a rotating shaft is usually required. The coil and associated water quenching unit usually form a unit because of the importance of the location of the water quenching unit relative to the inductor. The water supply is usually supplied through the coil itself as shown in the diagram. Controlled scanning of the shaft by the induction coil and quench ring during rotation produces a controlled surface depth over an adjustable length of the shaft, all in an automatic cycle.

The control of the hardened layer depth depends on the power input from the generator and the downward speed of the shaft through the induction coil, while the length of the hardened section is controlled by a pyrometer set to specifications. Once the desired hardening layer depth and hardness pattern is found by matching equipment parameters, these settings can be kept consistent for a repeatable process for each part.

While the application described involves surface hardening, it is also applicable to other heat treatment operations that require progressive heating, such as annealing and tempering.

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