Induction Coil Layout for Faster Warm Stamping of Metal Plates
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Solution Overview
Problem
Conventional warm drawing methods for austenitic stainless steel require long heating times due to the limited heat capacity of heaters embedded in dies, leading to low productivity, especially for materials with low thermal conductivity like austenitic stainless steel, which restricts the ability to shorten heating times and improve manufacturing efficiency.
Innovation Solution
A manufacturing method involving local induction-heating of metal plates using a heating coil to heat areas with significant deformation to higher temperatures than areas with less deformation, allowing for faster reduction in tensile strength and improved productivity by arranging the heating coil to face outer areas with higher deformation, thereby reducing heating time and enhancing stamping efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cartridge heater is embedded in a die to heat the metal material, then the metal material can be heated to reduced tensile strength, but the heating time becomes excessively long due to limited heater size and low thermal conductivity of austenitic stainless steel
Solution Approach 1:
The patent replaces the conventional cartridge heater (mechanical/thermal contact system) with an induction heating system that uses electromagnetic fields to directly heat the metal material. This substitution eliminates the need for thermal conduction through the die and heater, enabling rapid heating of austenitic stainless steel without being constrained by the heater's physical size or the material's low thermal conductivity.
Solution Approach 2:
The induction heating is performed as a preliminary step before stamping, heating the metal material to the appropriate temperature range in advance. This preliminary heating action reduces the tensile strength of the material before deformation, making the subsequent stamping process more efficient and reducing the required pressurizing capability.
2Temperature
If the die is heated to a temperature equal to or higher than the metal material to ensure sufficient heating, then the metal material tensile strength is reduced, but the heating time increases due to the die's large heat capacity
Solution Approach 1:
The induction heating system directly generates heat within the metal material through electromagnetic induction, bypassing the need to heat the die first. This eliminates the thermal inertia problem associated with heating the large mass of the die, allowing the metal material to be heated quickly to the required temperature without being constrained by the die's heat capacity.
Solution Approach 2:
The induction heating system can selectively heat the metal material in the processing region without uniformly heating the entire die. This localized heating approach concentrates energy where needed, reducing the overall heating time while achieving the necessary temperature reduction in the metal material's tensile strength.
3Ease of manufacture
If conventional warm drawing is used to reduce tensile strength of austenitic stainless steel, then the material becomes easier to stamp, but productivity remains low at approximately 5 spm due to long heating times
Solution Approach 1:
By replacing the conventional cartridge heater with an induction heating system, the patent achieves rapid heating of austenitic stainless steel, reducing the heating time from minutes to seconds. This enables the stamping process to run at high speed (60 spm or higher) while still achieving the necessary reduction in tensile strength, thereby dramatically improving productivity.
Solution Approach 2:
The induction heating system allows for precise control of heating parameters such as power, frequency, and heating duration. By optimizing these parameters, the system can quickly achieve the appropriate temperature range for reducing tensile strength without excessive heating time, enabling high-speed stamping while maintaining ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the heating time required for metal components, increasing productivity from approximately 5 spm to 60 spm, while maintaining the tensile strength of areas with less deformation, thus improving the overall efficiency of metal component manufacturing.
Implementation Method 1
locally induction-heating a metal plate by a heating coil; at least a part of an area where an amount of deformation is relatively large in a processing region of the metal plate to be stamped is heated to a higher temperature
Data Source
AI summary
The manufacturing apparatus for a metal component includes: a preheating portion configured to locally induction-heat a metal plate; and a stamping portion configured to stamp the metal plate. The preheating portion includes a heating coil. The heating coil is arranged such that an axial direction of the heating coil is along a movement direction of the pressing portion and the heating coil faces, in the axial direction, an area where an amount of deformation is relatively large in a processing region of the metal plate to be stamped by the stamping portion. The heating coil is configured such that at least a part of the area where the amount of deformation is relatively large in the processing region of the metal plate is heated to a higher temperature than an area where the amount of deformation is relatively small in the processing region.