Round steel heating forging equipment

Introduce： Round steel heating forging equipment is often used for heating forging or annealing of round bars and sheets. It provides the selection method of round steel heating forging equipment, the selection of round steel heating forging equipment body structure, and the power supply selection of round steel heating forging equipment. Method, method for selecting parameters of round steel heating forging equipment.

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20mm bar induction heating forging furnace

Introduction

Consultation

The complete set of automatic round steel heating forging equipment consists of: intermediate frequency power supply, capacitor cabinet, inductor, automatic feeding rack, unloading rack and control cabinet. The intermediate frequency power supply adopts a split structure design, and the power cabinet is a GGD standard cabinet. The capacitive cabinet and inductor are compact in design and increase heating efficiency.

Reasonable control of the distance between the inductor and the heated round steel shortens the exposure time of the red hot round steel in the air, reduces the scale of the round steel , and reduces the energy consumption. The speed of the transmission mechanism is automatically controlled according to the process parameters set by the user. When there is no workpiece in the sensor, the automatic control system automatically reduces the output power of the intermediate frequency power supply; the workpiece enters the sensor, and the automatic control system automatically increases the output power of the intermediate frequency power supply.

Round steel heating forging equipment technical parameters summary table

Summary of technical parameters of round steel forging electric furnace with power less than 1000KW
Rated power(KW )	Rated frequency (HZ)	Transformer capacity (KVA)	Secondary voltage (V)	Number of commutating pulses	Sensor voltage(V)	Power consumption (KW.h/t)	Round roddiameter ( mm )
80	1000~8000	100	380v	6 Pulse	800	450	Φ 6-35
100	1000~8000	160	380v	6 Pulse	800	450	Φ 25-40
120	1000~8000	200	380v	6 Pulse	800	450	Φ 30-50
160	1000~8000	250	380v	6 Pulse	800	450	Φ 40-60
200	1000~8000	315	380v	6 Pulse	800	450	Φ 40-60
250	1000~8000	400	380v	6 Pulse	800	450	Φ 60-80
350	1000~8000	500	380v	6 Pulse	800	450	Φ 80-120
400	500~8000	500	380v	6 Pulse	800	450	Φ 80-120
500	500~8000	630	380v	6 Pulse	800	450	Φ 120-150
1000	500~1000	1250	660V-380V	12 　 Pulse	1200 / (800)	380	Φ 150-250
1500	500~1000	1600	Φ 660V-380V	12 　 Pulse	1200 / (800)	370	Φ 250-400
2000	500~1000	2200	Φ 660V-380V	12 　 Pulse	1200 / (800)	360	Φ 400-800

Round steel heating forging equipment application assembly drawing

Round steel heating forging equipment application areas:

Forging heating: used for round steel, round steel, square steel, steel plate heating, temperature compensation, blue quenching, on-line heating, local heating, metal material online forging (such as gears, semi-shaft connecting rods, bearings, etc.) Extrusion, hot rolling, heating before shearing, spray heating, thermal assembly, and heating, annealing, tempering, etc. of the entire metal material.

Heat treatment: mainly for shafts (straight shaft, variable diameter shaft, camshaft, crankshaft, gear shaft, etc.); gears; sleeves, rings, discs; machine tool screws; guide rails; planes; ball heads; hardware tools, etc. Surface heat treatment of mechanical (automobile, motorcycle) parts and heating, annealing, tempering, etc. of the entire metal material.

What parameters are required for the selection of round steel heating forging equipment?

The selection of round steel heating forging equipment generally requires the following parameters:

First: the shape of the heated workpiece, the outer dimensions, and the weight of the heated workpiece.

Second: the material material of the heated workpiece (generally induction heating, only for metal conductor materials).

Third: the time of the target temperature required for heating the heated workpiece, and the target temperature.

Once the above three points are clear, the round steel heating and forging equipment can be selected including matching power.

What are the characteristics of the furnace structure of round steel heating forging equipment?

1. Furnace structure: Our company's heating furnace is designed as an overall quick change type. Quick change is possible when changing the furnace body for different heated workpieces.

2. Furnace lining: The lining is made of silicon carbide or integral knotting, and the temperature is above 1450 °C.

3. Protection: Automatic shutdown when the water temperature exceeds 65 °C.

4. Induction furnace water cooling rail: Water-cooled rail is installed on the induction furnace lining.

How to calculate the power supply of round steel heating forging equipment?

P=(0.168×200×693)/(0.24×0.6×145)=1029KW In the formula: 0.168—the average specific heat of the ferrous metal; 2080—the mass of the workpiece (Kg); 200—the temperature rise of the workpiece heating; 0.24— Work heat equivalent; 0.6 - average efficiency (0.6 in this case, generally 0.5 ~ 0.65, lower profile sensor, take 0.4); 145 - work beat (seconds)

According to the above calculation, a 1KHz induction heating device with a rated power of 1500 KW can be configured to meet the needs.

How to choose the power frequency of round steel heating forging equipment?

The choice of power frequency follows the principle of optimal heating efficiency and temperature uniformity (core temperature difference). The higher the frequency, the higher the heating efficiency, but the too high frequency is likely to cause the surface of the workpiece to be too burnt. According to our experience, the frequency is selected to be 2500KHZ. , the best heating effect can be obtained without overheating the workpiece temperature.

How to choose and use round steel heating forging equipment? Mainly from several aspects:

1. Shape and size of the heated workpiece

For large workpieces, round steels and solid materials, round steel heating forging equipment with high relative power and low frequency should be used; for small workpieces, pipes, plates, gears, etc., round steel heated forging equipment with low relative power and high frequency should be used.

2. Depth and area required for heating

Deep heating depth, large area, overall heating, should use high-power, low-frequency round steel heating forging equipment; shallow heating depth, small area, local heating, the use of relatively low power, high frequency round steel heating forging equipment.

3, the required heating rate

The required heating speed is fast, and the round steel heating forging equipment with relatively large power and relatively high frequency should be selected.

4, the continuous working time of the equipment

The continuous working time is long, and the round steel heating forging equipment with slightly higher power is used.

5, the connection distance between the sensing component and the device

The connection length is long, and even the use of water-cooled cable connection is required. The medium-frequency induction heating furnace with higher power should be used relatively.

6, process requirements

In general, quenching, welding and other processes, relatively power can be selected smaller, frequency selection is higher; annealing, tempering and other processes, relative power selection is larger, frequency selection is lower; red punch, hot calcination, smelting, etc., need For a heating process, the power should be chosen to be larger and the frequency selected lower.

7, the material of the workpiece

The relative power of the high melting point of the metal material is larger, the relative power of the lower melting point is smaller, the power of the smaller resistivity is larger, and the power of the larger resistivity is smaller.

Round steel heating forging equipment has significant advantages:

1. Compared with traditional heating means (oil, coal, gas), it has the remarkable advantages of environmental protection, energy saving, convenient operation and low labor intensity;

2. Compared with the thyristor intermediate frequency, the energy saving is 10%~30%, and there is no harmonic interference to the power grid;

3. Compared with the resistance furnace, the energy saving is 50%~60%;

4. It has the advantages of fast heating, uniform heating, no oxide layer and good product quality for customers' products;

5. The sensor is isolated by a transformer and is very safe.

6. Environmental protection: no pollution, noise and dust.

7. Adaptability: It can heat various workpieces with different shapes.

8, the equipment occupies a small area, less than two square meters, to facilitate customers to maximize the use of production space.

Why is the round steel heating forging equipment highly efficient?

The principle of round steel heating forging equipment is electromagnetic induction, and the heat is generated in the workpiece itself. The ordinary workers can carry out the continuous work of forging task ten minutes after working on the round steel heating forging equipment , without the need for the professional workers to burn the furnace in advance. Sealing the furnace work. Don't worry about the waste of the heated billet caused by the power outage or equipment failure. Because the heating method has a fast heating rate, the oxidation is very rare, and at least the steel raw material is saved per ton of forgings compared with the coal burning furnace. 50 kg, its material utilization rate can reach 95%. Because the heating method is evenly heated, the core surface temperature difference is very small, so the forging die life is greatly increased in forging, and the surface roughness of the forging piece is also less than 50um. Induction heating The heat is generated in the workpiece itself, so the heating is uniform, and the temperature difference between the core and the core is very small. The temperature control system can realize the precise control of the temperature to improve the product quality and the pass rate.

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