Analytical and fem modeling of aluminum billet induction heating with experimental verification

Abstract

Induction heating is commonly used in the re-heating of aluminum billets before forging or extrusion. Powerful finite element modeling (FEM) tools are available to assist in the design of such processes; however, such models should be validated by comparison with analytical solutions or experimental results to ensure accuracy. Induction heating experiments have been performed using a number of different coil designs and work piece dimensions at 50 Hz. Aluminum alloys with different electrical conductivities have been used, i.e. 6060 and A356. Process parameters such as: current, power, magnetic field, electrical conductivity, etc. have been measured with high precision instrumentation. Experimental data are presented and compared with equivalent 1D analytical and 2D axial symmetric FEM modeling results. The effect of frequency on the induction heating process is reviewed using the validated analytical and FEM models. Some recommendations are given with respect to appropriate modeling techniques, boundary conditions and numerical mesh sizes.