Abstract

Due to growing challenges regarding crash-performance, CO 2 emission as well as increasing demand for lightweight construction, hot forming of car body parts has risen to one of the most important technologies for saving weight of a car body. During hot forming shaped blanks of steel are heated and austenitized at around 950 °C and subsequently quenched for martensitic formation. Currently the heating is realized in roller hearth furnaces which allow only a slow heating and, therefore, limited production. Additionally, due to the indirect heating principle of roller hearth furnaces the energy efficiency is low. Induction heating for hot metal forming offers a big potential to increase the production rate dramatically and also to improve the energy efficiency. Only due to the fact, that the heated parts typically are already pre-shaped and mostly have already holes and cut-outs induction heating becomes a very complex task. The paper describes the numerical and experimental investigation and the optimization of a single-stage induction heating process for hot forming of pre-shaped blanks and gives design rules for an optimized induction heating system.

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