Localized Induction Heating for Large Titanium Alloy Forming
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Solution Overview
Problem
Existing methods are inadequate for forming very large thick parts, particularly those made from materials like titanium alloy TA6Vbeta, which are unsuitable for cold forming, and conventional hot forming techniques are limited by size and cost constraints.
Innovation Solution
A device employing localized hot forming using induction heating, where only the part to be deformed is heated by an inductor placed opposite and not surrounding it, allowing for deformation in a cold press, which is more cost-effective and size-unrestricted compared to traditional heated presses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional hot forming with general heating of the part and tool is used, then the material can be deformed, but the equipment size and investment cost increase significantly
Solution Approach 1:
The patent applies localized induction heating to heat only the specific region of the part that needs to be deformed, rather than heating the entire part and tool. This localized approach allows hot forming to be performed using a cold press, significantly reducing equipment size and investment cost while achieving the necessary temperature in the deformation zone
Solution Approach 2:
The patent replaces the conventional thermal heating system (heated press) with an induction heating system. This substitution allows the use of a cold press instead of an expensive heated press, reducing equipment complexity and cost while maintaining the ability to perform hot forming
2Ease of manufacture
If cold forming is used on thick parts made from materials like titanium alloy TA6Vbeta, then the process is simpler, but the material cannot be deformed without degrading mechanical performance
Solution Approach 1:
The patent applies preliminary localized heating to the deformation zone before forming. This pre-heating of the specific region to be deformed allows the material to become more ductile and easier to form, while the rest of the part remains at ambient temperature, preserving its mechanical properties
Solution Approach 2:
The patent creates a local temperature difference where only the deformation zone is heated to the appropriate temperature for deformation, while the rest of the part remains cold. This localized thermal treatment enables deformation in the heated zone without affecting the mechanical performance of the unheated portions
3Temperature
If the part is surrounded by an inductor for induction heating, then heating is more uniform, but the device complexity and size increase
Solution Approach 1:
The patent uses a linear inductor configuration that heats only the specific linear zone that needs to be deformed, rather than surrounding the entire part. This localized approach simplifies the inductor design and reduces device complexity while maintaining adequate heating uniformity in the target zone
Solution Approach 2:
The patent extracts only the necessary heating function from the conventional surrounding inductor design. By using a linear inductor placed adjacent to the part rather than surrounding it, the design achieves the required localized heating with reduced complexity and size
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
Enables greater elongation before rupture and stress relaxation in the material, facilitating the formation of large parts like aircraft structural elements with improved mechanical performance without degrading the material's properties.
Implementation Method 1
the device uses induction heating so that only the part to be deformed is heated
Implementation Method 2
at least one step of applying an induction field localized adapted to bring an identified part of the part to a temperature adapted to the deformation of said part
Data Source
Figure 1A~1C
Figure 2~3
Figure 4~6B
AI summary
The method involves positioning of a part (2) in a cold press comprising an inductor (4). A localized induction field is applied and adapted to bring an identified part (10) of the part at a temperature adapted to the deformation of the part. A deformation tool is applied on the heated identified part. A hot forming of the identified part is carried out by the tool. A piece is positioned in a cold press such that the piece is positioned on a lower matrix (1a) and a less pressurized installation positioned on the part of an upper matrix (1b) is provided with the inductor. An independent claim is also included for a device for forming a part comprising an inductor.