Numerical study of the induction heating of aluminium sheets for hot stamping

Abstract

Induction heating is one of the most popular metal heating technologies because of its high heating rate and high energy efficiency. This method is suitable for heating workpieces/blanks in different shapes, sizes and materials. Induction heating of metal sheets has been investigated by various research organizations and industrial companies. However, information concerning the induction heating of aluminium blanks is limited. Further, investigations were required by industries to address the issues relating to the uneven temperature distributions developed in the metal sheets so that an optimized design could be developed to help the enhancement of the technology. Aiming at the study of the induction heating process for hot stamping, especially the temperature distribution developed in the aluminium sheets, this paper presents in-depth analysis of induction heating using 3D FE simulations, involving uses of DEFORM and COMSOL. Different coil arrangements, level of powers, frequencies, cycle times, etc. have been modelled and simulated to examine their effects on the heating efficiency and developed temperature profiles in the Aluminium sheets. It is revealed from the simulations that design features in the induction coils like shapes of cross-sections and angles of coil corners affect the uniformity of the developed temperatures in the metal sheets. Heating with an optimized combination of the coil design and the power setting could help to achieve higher heating rates and temperature uniformity. Nevertheless, the application could be constrained by some practical factors.

Keywords

• Hot stamping
• Temperature
• Simulation