Design of Induction Heating Devices Using ELTA

and 2DELTA Software

V. Bukanin, A. Zenkov, A. Ivanov
Department of Occupational Safety
St. Petersburg Electrotechnical University (LETI)
St. Petersburg, Russia
[email protected]

Abstract—This work deals with investigating of heat these processes, first of all electromagnetic effects (“skin”,
treatment and forging steel billets of round and rectangular “proximity”, “edge”, “end”, “electrodynamics” effects, etc.).
cross-section using induction method of heating. Several These effects play a dramatic part in uniformity, productivity,
industrial processes and induction installations used nowadays efficiency and safety of induction heating. It is important to
are very old and have to be sufficiently improved from technical choose frequency of power source, parameters of induction
and economical point of view. The first steps “Conceive – Design” coils and other parameters with particular care to meet the
before “Implement - Operate” ones need detail experimental and necessary requirements of heating technology. It is hard to
calculation investigations. imagine that the new induction installation can be created
The general-purpose FE programs such as Flux 2D and 3D, without detailed investigation and analysis of the induction
Ansys, etc. are rather complicated and time - consuming software
system. However, the typical mistakes in designing process
to realise computer simulation. In multi-stage induction lines, the
number of stages and the overall space are very big, that creates
are met even at present. The developers and constructors of
difficulties in using these programs. The ideology of ELTA installation must correctly choose power source,
programs is different. The engineering programs do not require configuration, turn number, type and size of the coil tube,
special knowledge in computer simulation due to simple self- thickness of heat insulation, the electric or mechanical drive
explanatory interfaces, preinstalled design options and database. for moving of workpieces, cooling system, control system of
This presentation is devoted to design of induction systems temperature and other elements.
using programs ELTA 6.0 and 2DELTA. ELTA is a program
First developers and researchers of induction melting
based on 1D and 2D Finite Difference Method (FDM) with semi-
furnaces and heating installations used experimental,
analytical account for the lengths of individual inductors and
loads. Calculations in ELTA are designed “in series of steps”, i.e.
approximate or complex analytical methods of calculation to
power and temperature are calculated for each heating stage understand the occurring phenomena. Making these routine
(inside the induction coils) and “cooling” stage (spaces between design calculations was a very difficult and time-consuming
coils, quenching and holding zones). 2DELTA provides a two procedure. Extensive work is being carried out in the field of
dimensional simulation of electromagnetic and thermal fields in numerical methods of calculation and computer simulation
cylindrical induction heaters using both integral and differential programs. In our days many types of programs are used in the
numerical methods. Multiple tests and comparison of simulation investigation of induction heating processes. Very rarely
and experimental results show good accuracy of these programs. developers use semi-empirical methods of calculation to
Description of the computer assisted design of induction lines obtain even main integral parameters of inductor or analytical
is illustrated by several examples methods to investigate the problems of heating.

Keywords— induction heating, computer simulation, ELTA It is obvious that computer simulation must be used at both
program phases of the project development. There are many programs
for simulation of induction systems, such as Flux 2D and 3D,
Ansys Multiphysics, ThermNet, Magnet, Sysweld, Comsol,
I. INTRODUCTION
and others [2]. These programs are mainly based on Finite
The first inventions and further developments of induction Element (FE) method that allows the users describe and
heating have opened enormous possibilities in using this type simulate 2D and 3D systems of complex geometry. They are
of heating for different technological processes [1]. Other expensive and require well-trained operator to run them
things being equal, induction heating has many advantages effectively.
compared to the other traditional heating technological
processes. This statement is widely known and there is no Up to now many typical cylindrical and flat workpieces are
need to spend precious time studying this question in any used in industry and have to be heated in induction installation
literature sources. It may be pointed out that the given type of for different technologies. ELTA 6.0 (Electro-Thermal
heating is very complex due to the hidden from view internal Analysis) and 2DELTA (Two Dimensional variant for
processes in induction systems, so engineering design and cylindrical systems) are the subject oriented programs
investigation of induction heaters is very interesting and developed by induction experts for induction people for design
creative job to solve the necessary practical tasks. Only of induction heating equipment, investigation and study of
experienced researchers and developers know particularities of processes. These programs open wide opportunities for the

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specialists employed in design and production of induction Main attention was paid to the “edge” effect of load. It
heating installations. They allow quick obtaining of rather describes distortion of the electromagnetic field, current and
accurate results for typical practical applications of induction power distributions caused by abrupt change in geometry or
heating. Advantages of programs consist in opportunity of material properties in the eddy current flow path, e.g. near the
their use without special training and programming skills, edges of a strip [3]. Results of simulation in Fig. 2 show that
good for practical tasks accuracy and a lot of additional frequency 2400 Hz gives overheating of central zone (X = 1.2
options such as water cooling of the coils, convenient cm, Y = 0 cm), frequency 8000 Hz gives overheating of edge
database, multiple modes of coil energizing and circuits for zone (X = 0, Y = 4 cm).
power delivery, etc.
Several results of investigation obtained by these programs
are described in [3] – [5]. For example, the important problem
of high temperature heating the workpieces of square cross-
section from cracking sensitive steel was solved by using
combined installation consisting of low intensive induction
pre-heating line, gas fire furnace and induction post-heating
line.
New results of investigation for two industrial applications
and induction heating technologies are described below.

II. HEATING OF RECTANGULAR CROSS-SECTION BILLET

Heating system and technological requirements: it was
necessary to design the induction system for continuous
heating of steel spring billets prior forging process up to final
temperature on the output of inductor 1020±20 °C. Fig. 2. Color map of temperature in the ¼ of cross-section after induction
heating (top – 2400 Hz, bottom – 8000 Hz)
Billet dimensions: thickness 2.4 cm, width 8 cm, length 60
cm. Material – carbon steel 1040. The best design was selected after several iterations. In this
case it is convenient to use the special graph of temperature
Processing parameters: frequency of power source is 1000
distribution along the perimeter of ¼ cross-section (Fig. 3).
– 8000 Hz, power is 180 – 185 kW, and production rate is
1.56 t/hr. Speed of moving and heating time can be found
knowing production rate.
It is natural to start from traditional type of induction
heater, i.e. a continuous heater with induction coils of
rectangular configuration (Fig. 1).

Fig. 1. Sketch of induction system

Inductor parameters: “the window” of inductor – 4.2×13

cm, the length 36 cm, the number of turns 11 of copper tube
2.8×2×0.15 cm. Heat insulation – Thermal insulation: not
applicable.
Billets are moving through the inductor in longitudinal
direction. ELTA 6.0 program has an option for 2D FD
simulation of heating bodies with rectangular cross-section
and can simulate this variant of heating system.
The scope of investigation is obtaining the necessary final
temperature and reduction the temperature gradient to achieve
the technological requirements. This task has many parameters
that don’t allow us to use optimization methods or intuitively
predict the rational value of frequency. Operator-guided
design was used with expert evaluation of the results. Fig. 3. Temperature in the perimeter of ¼ cross-section after heating (top –
selected frequencies, bottom – optimal frequency)

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 After preliminary calculations the most perspective T×n, with T – rate of push and n – number of workpieces in
variants were selected and more detailed technical and the coil, i.e. time in each coil is 120 sec).
economic analysis was performed. As can be seen from Fig. 3,
the rational frequency range of power source is about 4500 – One of difficult simulation problems is to set the frequency
5000 Hz. Electrical efficiency of induction heating 70 – 77 % range of generator to match the load characteristics because its
for frequency 2400 – 8000 Hz respectively is high enough values can change in starting regime in very wide ranges when
from economical point of view. Temperature differences in the workpieces heat from 20 to 1200 qC.
cross section can be decreased from ΔT = 150 K (after It is very difficult to select the correct value of capacitance
induction heating with frequency 2400 and 8000 Hz) to ΔT = in both regimes. In starting regime capacitance must be less
100 K (optimal frequency 4800 Hz) respectively (Fig. 3). ΔT than in stationary one, but often controlling system of
equalizes quickly during transportation time and decreases generator in some cases doesn’t permit to start the heating
after 4 sec cooling to 30 K. process.
Result of 1D simulation in ELTA is shown in Fig. 5.
III. HEATING PRIOR HOT FORGING
It was necessary to create the induction heating line for hot
forging of steel billets.
The main problems that must be solved in the first step of
design are finding geometrical and electrical parameters of:
a) induction system (number and length of coils, turn
number and tube profile, internal diameter of coils, parameters
of thermal insulation, etc.);
b) power source (power, frequency, output voltage, etc.);
c) resonant circuit (series or parallel compensation, length
and profile of leads, capacity of tank, etc.).
Due to very fast simulation, it is easy to optimize the
process of heating in ELTA program, i.e. to find an optimal
variation of frequency and specific power versus time and,
Fig. 5. Temperature dynamics along the induction line (ELTA)
therefore, along the heating line.
Rational variant of system and results of investigation 2DELTA program can find more exact temperature
obtained by ELTA are presented below. Final variant of distribution taken into account the real length of billet (Fig. 6).
induction heating line to be investigated in detail consists of 2
parallel connected coils (Fig. 4).

Fig. 4. View of investigated induction system

Workpiece parameters: material – carbon steel 1040,

diameter 10 cm, length 10 cm.
Inductor parameters: Coil No 1: Internal diameter (ID) 16
cm, length 60 cm, turns number 25. Profile of copper tube
2×2×0.3 cm. Thermal insulation: Portland cement concrete,
thickness 0.5 cm, magnesite 0.5 cm.
Coil No 2: ID 16 cm, length 60 cm, turns number 45. Fig. 6. Temperature dynamics along the induction line (2DELTA)
Profile of tube 1×2×0.3 cm. Thermal insulation: Portland
cement concrete, thickness 0.5 cm, magnesite 0.5 cm. Main attention was paid to:
Processing parameters: final temperature of semi a) distribution of temperature along the length and
continuous heating is 1220±50 °C, frequency of thyristor radius of workpieces, mainly at the last one on the exit from
inverter in stationary stage of heating is 1100 Hz, constant coil inductor and comparison to technological requirements
voltage is 430 V (coils are connected in parallel) and (quality of heating);
production rate is 1.11 t/hr. Rate of push 20 sec and
b) investigation of “end” effects, e.g. how the
calculation time are found knowing production rate
displacement of inductor and workpiece end parts can
(calculations are made in time, which is related to position of
influence on power sources and temperature taking into
the test point on the part surface in a real process of heating t =
account the heat losses.

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 Technological process usually requires uniform There are three variants to improve the negative situation:
temperature distribution on the length of the last billet. The increase the displacement of inductor and billet end, increase
additional thermal losses on the end surface of billet can be frequency and use the end insulation cover. All variants may
compensated both by increasing the power at the end zone and have its disadvantages – decrease in the electrical efficiency,
by insulation cover. The “end” effects of inductor and increase in the temperature difference along the radius and
cylindrical load define the uniformity of heating and may be inconvenience in the using the end insulation cover
used in semi continuous heater. These effects are caused by respectively.
magnetic field distortions near the ends of the workpiece or
the coil. For steel after Curie point the workpiece “end” effect
is always positive (power increases to the end). In a real
induction system, the coil and workpiece “end” effects
interfere. It means that there is optimal value of billet
displacement into induction coil to compensate the end losses.
The “end” effects can be characterized by distribution of
normalized surface specific power along the billet length as
shown in Fig. 6. Specific power on the end part of billet is
1.15 times more than in the middle part.

Fig. 9. Color map of temperature on the final stage

Simulation of induction heating system with end

insulation cover shows that temperature gradient can be
decreased up to 47 K.

IV. CONCLUSIONS
The obtained by ELTA and 2DELTA results of
investigation were used to design the rational variants of new
induction systems and technologies for industrial heat
treatment and hot forging processes. It is shown that the
Fig. 7. Distribution of surface specific power along the length problem of “edge” effect for rectangular cross section billets
and “end” effect for cylindrical billets requires the special
As the last billet is in direct contact with air at the exit of attention to avoid the typical mistakes in the process of design.
induction heating coil line, there are additional energy losses A decision has been made to choose optimal values of
and consequently lower temperatures as well scale due to the frequency, parameters of induction coils and other parameters
chemical reaction of Fe and O2 for one pusher cycle time (Fig. to meet the necessary requirements of heating technology.
8).
The subject oriented programs ELTA 6.0 and 2DELTA are
very convenient in the design process of induction heating
equipment and technologies permitting fast simulation many
variants to find the rational decision.

REFERENCES
[1] Muehlbauer, A., History of Induction Heating and Melting, Vulkan
Verlag, 2008, 202 p.
[2] V. Nemkov (2009), Modeling of induction hardening processes.
Chapter 10 in Handbook of Thermal Process Modeling of Steels.
CRC Press, London, New York, 498.
[3] V. Nemkov, V. Bukanin, A. Zenkov, A. Ivanov, “Simulation of
induction heating of slabs using ELTA 6.0,” in Proc. of International
Scientific Colloquium Modelling for Electromagnetic Processing,
Hannover, Sept. 16-19, 2014. pp. 113 – 118.
Fig. 8. Distribution of temperature along the length [4] V. Vologdin, Vl. Vologdin, Jr., V. Bukanin, A. Ivanov, “Practice of
Computer-Assisted Design of Induction Installations,” in Proc. of
International Scientific Colloquium Modelling for Electromagnetic
Temperature map feature from 2DELTA calculation helps Processing, Hannover, Sept. 16-19, 2014. pp. 313 – 318.
to design the temperature gradient along the length and radius [5] V. Bukanin, A. Ivanov, A. Zenkov, and V. Nemkov, “Design of
of billet (Fig. 9). As can be seen from Fig. 8 and Fig. 9, induction heating lines using ELTA program,” in Proc. of the 8th
temperature differences in the volume is 62 K. International Conference on Electromagnetic Processing of
Materials (EPM 2015), Oct. 12-16, 2015, Cannes, France. pp. 545 –
548.

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