SYNOPSIS

The project setup is used to heat steel-work piece for forging & melt aluminium for
foundry, used by students to conduct experiments for academic purpose.
Induction heating & induction melting methods are widely used in metal industries
because of its heating efficiency, high production rate & clean working environment.
The inductor coil is similar to a transformer primary and the work piece is euivalent to
the transformer secondary, when electricity is passed in the coil, !"# is formed in it. $ddition to
this reverse !"# is spontaneously created in the work piece generating magnetic flux. This
magnetic flux changes freuently corresponding to flow of current in the coil resulting in
generation of heat inside the work piece & rising its temperature.
This setup is actually an energy transfer device where energy is transferred directly from
copper coil turns into #e-material which is subjected through the electromagnetic field produced
by the copper coil.
This project involves combination of both aluminium melting & steel heating methods
using a single induction coil for small scale production purpose.
This design posses semi helical coil with %-shaped copper tube turns, which is uniue in
fabrication compared to conventionally used in industries, which is open- air cooled protected
with ceramic body.
&ere we use proper power rating for system with help of '((volts step up transformer
connected to controlling device hence powered to induction coil with leads. In this way, we raise
the temperature of steel work piece placed inside the coil. It is possible to achieve red hot steel
about )(((
o
c i.e., forgeable point.
#or melting aluminium we select hollow steel tube structure which is coated by ceramic
or lime layer as it protects steel from reacting with aluminium and is designed to placed between
the induction coil. The aluminium billet is fed through hopper into the tube & gets heated from
the inner surface of steel tube by induction process which can melt it to liuify aluminium
around the temperature about *+(
o
c.
The liuid aluminium is poured out using rack & pinion tilting mechanism for
considerable angle at one side of the coil aided with triangular sliding support between rack &
coil base actuated by manual operated circular disc.
The whole setup is placed on table at an considerable height for pouring.
#inally, perforated ceramic outer body protection is covered around the coil to resist heat
from coil by an operator and also this perforated holes helps to observe work piece heating and
air circulation for cooling coil turns.