Abstract
A non-linear mathematical model intended for calculating the electrical and thermal characteristics of an induction crucible furnace with a conducting ferromagnetic crucible is developed using the finite element method. The furnace electrical characteristics as functions of the inductor frequency, temperature, and current are studied. The non-stationary thermal problem is solved. The mathematical model has been implemented in the ELCUT software package. Three furnace operation modes typical for melting of metals are identified and investigated: cold, in which the ferromagnetic crucible temperature is below the Curie point (723 °C), and the metal loaded into the crucible is in the form of lump charge; transitional, in which the crucible temperature is below the Curie point, and the metal inside the crucible is in liquid state; and hot, in which the crucible temperature is above the Curie point, and the crucible is in nonmagnetic state. The resistance and inductance of the “inductor–charge” system as functions of the frequency, temperature and current are obtained in the Simulink/ Matlab environment. An experimental bench consisting of an induction crucible furnace with a ferromagnetic conducting steel crucible, a high-frequency adjustable transistor power supply, a microprocessor control system, and a data acquisition system is developed. An experiment on a laboratory furnace equipped with a steel crucible and with an aluminum alloy charge was carried out. The experimental results are in good agreement with the mathematical simulation results, which confirms adequacy of the mathematical model.
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