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Computer Modeling [.pdf format]

Tips for Computer Modeling of Induction Heating Processes, Part 2

Author: Valery Rudnev
Publication: Forge Magazine
Date: 10/1/2011

Many of the bars, billets or rods being manufactured today lend them selves to processes in which it is required to hot form only a certain part of the workpiece, for example its end. Article discusses specifics of computer modeling of end heating applications and critical tips executives must know regarding computer simulation of induction heating processes prior to metal's warm and hot forming.

Computer Modeling Helps Prevent Failures of Heat Treated Components

Author: Valery Rudnev
Publication: Advance Materials and Processes
Date: 10/1/2011

Consider this scenario. Following the development stage, an induction hardening machine is built, completes a successful run-out, and is shipped to the customer. After a number of successful production runs, parts begin to experience cracking during the hardening operation. A check of induction machine process parameters (power, frequency, quenchant temperature, concentration, pressure and flow, part positioning inside induction coil, etc.) shows everything is in order. The question is why does cracking in parts suddenly occur? An article discusses some of subtleties related to this issue.

Computer Modeling Helps Identify Induction Heating Misassumptions and Unknowns

Author: Valery Rudnev
Publication: Industrial Heating
Date: 10/1/2011

Whenever someone is discussing about induction heating, reference is often made to the skin effect phenomenon that is a fundamental property of induction heating. Unfortunately, many people do not aware that the widely used assumption regarding current and power distribution due to a skin effect is not valid for great majority of induction surface hardening applications. Computer modeling helps to unveil this common misassumption.

Tips for Computer Modeling of Induction Heating Process

Author: Valery Rudnev
Publication: Forge Magazine
Date: 7/1/2011

Certain numerical computational methods or software are preferred for each family of induction heating applications. There is not a single universal computational method that optimally fits all types of applications. In recent years, the finite element method (FEA) became the dominant numerical simulation tool for a variety of engineering applications. Though FEA is a very effective modeling technique, it is not the ultimate computational tool for all induction heating applications. In some cases a combination of alternative methods is more effective. Article provides a short comparison of different computer modeling techniques used to simulate induction heating processes. Case study of computer modeling of FluxManager Technology is provided here as well.

Computer Modeling of Induction Heating: Things to be Aware of, Things to Avoid

Author: Valery Rudnev
Publication: Industrial Heating
Date: 5/1/2011

Great majority of commercial codes used for computer modeling of induction heating processes are all-purpose programs. Regardless of well-recognized impressive capabilities of modern commercial simulation tools, some of generalized programs experience certain difficulties in taking into consideration certain features of a particular induction heating application. Therefore, be aware, that some critical feature(s) of a particular induction heating or induction heat treating application could be limiting factor creating considerable challenges for a majority of presently available generalized (all-purpose) commercial software affecting an accuracy of simulations. This article discusses things to be aware of and things to avoid in respect to choosing a proper software for modeling induction heating applications.

Intricacies of Computer Simulation of Induction Heating Processes

Author: Valery Rudnev
Publication: Proceedings of the 28th Forging Industry Technical Conference, Schaumburg, IL
Date: 4/5/2011 - 4/7/2011

In the last decade, when discussing subjects related to a computer simulation of induction heating, the word "usefulness" has been replaced by a word "necessity". Combination of a sophisticated engineering background with advanced process simulation software that is capable to effectively model electromagnetic and thermal phenomena, induction heating professionals possess the unique ability to analyze, in few hours, complex technological problems. Computer modeling provides the ability to predict how different, interrelated and non-linear factors may impact the transitional and final thermal conditions and what must be accomplished to improve the effectiveness of the process, determine the most appropriate process recipes and serve as a comfort factor when designing new systems. Article discusses different aspects related to capabilities to computer model modern induction heating process, limitations of generalized commercial software, common incorrect assumptions, peculiarities when induction heating non-cylindrical workpieces, etc.

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