February 2021 Volume 3

AUTOMATION

Most aluminum alloys require forge temperatures up to 750-900F. With the melting temperature of some alloys being just 100F higher, billet position and induction coil design are critical. Some aluminum forging processes require preheating prior to coating and a final heating prior to forming. These systems become a bit more complex to design. Usually, a single induction power supply can be used with two induction coils in series, but the key to automation is how to move the parts out of one coil, into the coating tank, and into the final heat coil. Some turnkey systems are designed with an integrated lubricant dipping station. These dipping systems use vertical pneumatic actuators and cages to dunk the part. Others use rotary actuators and gages as well. However, lubricant can cause premature mechanical issues with sprockets and cylinders. Newer systems rely on robot technology for holding and dunking parts. If appropriately designed, robot end-effect tooling should last substantially longer than sprockets and cylinders.

Figure 12. Multi-position induction bar heating system The rings will be pushed up pneumatically one part at a time vertically through a set of one-way fingers under the induction coil, creating a stack of billets inside the coils. As a ring is inserted through the bottom of the coil, a specialized liner is in place to aid in minimal friction and wear. When the stack fills the coil and the next ring is loaded into the coil, a heated ring is lifted out of the top of the coil where it is pushed horizontally off the stack and deposited onto small exit discharge conveyor for the robot to load the forging press. Similar in concept to a ring heater, aluminum pucks can be automated with like components. However, design modifications must be considered when handling and induction heating non ferrous metals. Induction Heating &Automation of Aluminum With the evolving automotivemarket and light-weighting becoming increasingly important, many companies have moved to using aluminum as a replacement for steel due to ability to easily fabricate into shapes, low density (3x lighter than steel) and good corrosion resistance. With this material change, there have been many advancements of induction heating and automation of aluminum in recent years. Design considerations when automating an aluminum billet/ puck heater • Sensitive to temperature - Most alloys require forge temperature [750-900° ] to be 86-122°F from solidus. • Achieves uniform temperature faster and retains heat (thermal conductivity). • Material Handling. • Soft – scarring possible while being pushed through induction coil, susceptible to dents during loading and unloading, deforms when stacked and moved, dimples from thermocouples and push arms, possible to pick up impurities such as steel particles and other foreign contaminates during the process. • Hold back – magnetic field projecting billet out. • Reading Temperatures – pyrometer emissivity & thermocouple location. • May require a lubricant coating.

Figure 13. Vertical induction heating system for non-ferrous pucks Innovative automation solutions paired up with the latest advancements in induction heating will be critical to the forging industry's future and allow companies to be flexible and react quickly to changing market conditions. Today's manufacturing companies face new challenges that include the increase in market globalization, demands for greater productivity, increasing quality standards, energy consumption regulations, and changing skill requirements for industry employees. As a leader in the forging industry, Inductoheat is equipped and ready to assist forging companies with all types of automation to improve their forging process. ■ Mike Zaharof Regional Sales Manager Inductoheat 32251 North Avis Drive Madison Heights, MI 48071 Phone: 248- 217-8680 Email: mzaharof@inductoheat.com

FIA MAGAZINE | FEBRUARY 2021 37