We utilize the latest software versions of Flux 2D/3D and Elta 6.0 for electromagnetic and thermal computer simulation, with the ability to couple the results of simulation with other packages to model complex multiphysical processes such as stress and deformation phenomena. A majority of these projects are the result of industry demand, in cooperation with customers. We use simulation in all research and development projects for profound study of processes and optimal design of induction systems.
What is modeled
Fluxtrol’s simulation covers the electromagnetic and thermal processes in an induction system: the workpiece, the coil copper, magnetic flux controllers, and nearby bodies that absorb power. The effects of part geometry and material, motion, coil dimensions, flux controller shape and properties, power and frequency profile, quenchant and the coil cooling circuit can be examined, as described on the simulation page .
Tools
- Flux 2D and 3D. Finite element analysis for electromagnetic and thermal problems, including motion of the part or inductor.
- Elta 6.0. A 1D finite difference program with analytical formulations for 2D effects, quick for setting process parameters, with some customized 2D models for problems such as gear heat treatment and slab heating.
- Partner codes. Results are exported into complementary packages, as when Dante is used for metallurgical transformation, residual stress and deformation.
How a modeling engagement works
- Define the problem and the targets, whether a new coil or an existing process.
- Build 2D or 3D models and calculate heating, current distribution and electrical parameters.
- Couple results with other packages when stress, distortion or other physics matter.
- Optimize coil geometry, controllers, cooling and process parameters.
- Compare with experiment in the laboratory to confirm the model.
The same loop appears in the coil workflows : in the hairpin coil example, simulation and test results agreed closely on temperature distribution.
Examples from the literature
- A procedure was developed to account for magnetic losses in a concentrator inside Flux 2D, enabling temperature prediction for both copper and controller.
- Elta 6.0 was applied to slab heating in a longitudinal magnetic field, a 3D electromagnetic and thermal problem.
- ELTA and Dante were coupled to study stress and deformation in induction tube hardening.
- A paper on simulation accuracy discusses where inaccuracy comes from and what users must watch.
See the technical library .
Outcomes
Modeling lets teams evaluate designs before building hardware, predict power supply needs from voltage, current, power and inductance, understand why existing coils behave as they do, and pursue improvements with a validated model.
Start a modeling project
Contact Fluxtrol with your process and goals.
Real-world results
How Accurate is Computer Simulation of Induction Systems?
Discusses the sources of inaccuracy in electromagnetic and thermal induction simulation and what users must watch.
- Applies to software users and developers
Simulation of Induction Heating of Slabs using ELTA 6.0
Presentation on slab heating in a longitudinal magnetic field, a 3D electromagnetic and thermal problem.
- New ELTA program capabilities
Temperature Prediction and Thermal Management for Composite Magnetic Controllers
Procedure developed to account for magnetic losses in the concentrator within Flux 2D.
- Copper and controller temperatures