<p>The article explores an innovative, high efficiency heating system for forging tools designed for hot die forging processes. This environmentally friendly solution aligns with green technology principles. The temperature of forging tools is a critical factor affecting their durability and, consequently, the final cost of the forged product. Measuring this temperature presents a technical, technological and scientific challenge, particularly for forging tools used in the production of small-size die forgings. These tools are subject to fluctuating temperature conditions during the process, often due to the low heat capacity of the forgings themselves. The study included measurements of forging tools using both contact and non-contact methods. Numerical simulations were also conducted to determine forging tool temperatures at specific points. The results obtained from a thermovision camera, thermocouples and numerical modelling were compared. Based on a thorough analysis of the issue and the conducted research, a system for heating and reheating forging tools was developed, incorporating control over the heating rate to prevent local tempering. The induction heating device utilizes inductors with a total power of 30 kW, managed by signals from pyrometer sensors. A procedure for heating and reheating forging tools was established, based on signal analysis to initiate heating and maintain the desired temperature with maximum efficiency. The research confirms that the implemented heating and control system achieves very good results, significantly reducing the electric energy needed to stabilize forging tool operating conditions.</p>

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Development and Elaboration of a High Efficiency System of Heating and Reheating Forging Tools

  • Marek Hawryluk,
  • Łukasz Dudkiewicz

摘要

The article explores an innovative, high efficiency heating system for forging tools designed for hot die forging processes. This environmentally friendly solution aligns with green technology principles. The temperature of forging tools is a critical factor affecting their durability and, consequently, the final cost of the forged product. Measuring this temperature presents a technical, technological and scientific challenge, particularly for forging tools used in the production of small-size die forgings. These tools are subject to fluctuating temperature conditions during the process, often due to the low heat capacity of the forgings themselves. The study included measurements of forging tools using both contact and non-contact methods. Numerical simulations were also conducted to determine forging tool temperatures at specific points. The results obtained from a thermovision camera, thermocouples and numerical modelling were compared. Based on a thorough analysis of the issue and the conducted research, a system for heating and reheating forging tools was developed, incorporating control over the heating rate to prevent local tempering. The induction heating device utilizes inductors with a total power of 30 kW, managed by signals from pyrometer sensors. A procedure for heating and reheating forging tools was established, based on signal analysis to initiate heating and maintain the desired temperature with maximum efficiency. The research confirms that the implemented heating and control system achieves very good results, significantly reducing the electric energy needed to stabilize forging tool operating conditions.