Numerical modelling of induction heating for complex geometrical parts

Abstract : Electromagnetic induction heating is an efficient process allowing to directly heat up a prescribed area beneath the surface of metallic workpieces to enable quenching. This work presents a mathematical model for the coupled electromagnetic/heat transfer process as well as numerical solution methods. The electromagnetic model is based on a magnetic vector potential formulation. The source currents are prescribed using a voltage potential formulation enabling the modelling of arbitrary inductor geometries. The heat transfer problem is modelled using the classical heat diffusion equation. The electromagnetic model is fully transient, in order to allow the introduction of non-linear effects. The space discretisation is based on an edge finite element approach using a global domain including air, workpiece and inductor. The resulting linear system of equations of the implicit formulation is sparse and semi-definite, including a large kernel. It is demonstrated that a preconditioner based on the auxiliary space algebraic multigrid method in connection with a Krylov solver substantially reduces the solution time of the electromagnetic problem in comparison to classical solution methods and can be effectively applied in parallel. Applications for the heat treatment of a gearwheel and for an automotive crankshaft are presented. The surface heat treatment of complex geometrical parts requires the introduction of a relative movement of workpiece and inductor to ensure a homogeneous surface treatment. A novel method is proposed, which is based on a discrete level set representation of the inductor motion that can be used to generate conforming finite element meshes in a Lagrangian setting.
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Steffen Klonk. Numerical modelling of induction heating for complex geometrical parts. Other. Ecole Nationale Supérieure des Mines de Paris, 2013. English. ⟨NNT : 2013ENMP0077⟩. ⟨pastel-00982312⟩

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