Induction coil design has a major impact on process efficiency and final part quality, and the best coil design for your product largely depends on your application. Certain coil designs tend to work best with specific applications, and a less than optimal coil-application pairing can result in slow or irregular heating, higher defect rates, and lower quality products.
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First, consider these three factors
Part motion relative to coil
Several applications rely on part movement with the help of conveyors, turntables, or robots. A properly designed induction coil incorporates these individual handling requirements without the loss of heating efficiency.
Frequency
Higher frequencies are used for applications like brazing, soldering, annealing or heat treating, where surface heating is desired. Lower frequencies are preferred for applications requiring through-heating of the parts to the core like forging and die heating.
Powder-density requirements
Higher power densities are required for short cycle heating applications requiring high temperatures. Higher power densities may also be required to keep the hot zone confined to a small area, reducing the heat affected area.
different applications, Different coils
Annealing
- Simple solenoid coils (single- & multi-turn)
- Multiple position helical coils
- Pancake coils, transverse flux coils
- Channel coils
- High frequency
Bonding
- Simple solenoid coils (single- & multi-turn)
- Multiple position helical coils
- Pancake coils, transverse flux coils
- High frequency
Brazing
- Simple solenoid coils (single- & multi-turn)
- Contoured coils to match the shape of the part being heated
- Channel coils
- High Frequency
Curing
- Simple solenoid coils (single- & multi-turn)
- Multiple position helical coils
- Pancake coils, transverse flux coils
- Medium frequency
Forging
- Simple solenoid coils (single- & multi-turn)
- Multiple position helical coils
- Low frequency
Hardening
- Simple solenoid coils (single- & multi-turn)
- Multiple position helical coils
- Low frequency
Heat treating
- Simple solenoid coils (single- & multi-turn)
- High frequency
Melting
- Multi turn helical coils, heaving parallel water and electric paths
- Low frequency
Progressive hardening
- Simple solenoid coils (single- & multi-turn)
- Low frequency
Shrink fitting
- Pancake coils, transverse flux coils
- Channel coils
- Medium frequency
Soldering
- Simple solenoid coils (single- & multi-turn)
- Contoured coils to match the shape of the part being heated
- Channel coils
- High Frequency
Tempering
- Simple solenoid coils (single- & multi-turn)
- Multiple position helical coils
- Internal bore coils for internal diameter heating
- Channel coils
- Low frequency
Designing a coil for your application
Start with understanding where the heat needs to be generated in the part to perform the process, and then design the coil to achieve the heating effect. Similarly, frequency selection will depend on the induction heating application you’ll be using for your part.
Want to learn more? If you’d like to get an experienced set of eyes on your induction application, our team is available for consultation.
Contact us for help with your coil design needs!
Prices and Options
The price of induction forging machine varies greatly depending on the combination of power and frequency.
15 kW induction forge price
The most common high frequency 15 kW induction forging machine for sale on the market usually costs between $800 and $1200, and its frequency is usually between 30 kHz and 100 kHz. Its price varies by dealer, but their quality is not much different. If you buy it directly from China or eBay, you’ll also need to pay for shipping on it, which can be an extra $50 to $100 or so. The shipping cost is not fixed, it will fluctuate over time.
Contact us to discuss your requirements of high frequency quenching inductor. Our experienced sales team can help you identify the options that best suit your needs.
We’ve noticed there are sub-$600 machines on eBay, but we wouldn’t recommend buying it. Because after our research and investigation, these machines cannot work stably for a long time. If you buy it, you’ll probably pay more to fix it in the future.
large induction forging machine
The price of large induction forging machines is more expensive, which is inevitable. A 160 kW induction forging machine can cost over $10,000 depending on its frequency.
Other costs
As we all know, when you use an induction forging machine, you should also equip it with an essential water cooling system. You can use low-cost simple water cooling system, or use industrial chiller.
- Water pump + water container. A high frequency 15 kW machine requires a 0.37 kW pump and a pool or tank of at least 500L. A 0.37 kW pump costs about $80 to $120. The price of a 500L plastic water tank is about $50, and you can also DIY a pool. Note that you will also need a filter for your pump if there are impurities in the water. In hot summer, the machine may need more cold water, you can increase the number of water tanks or lower the temperature of the water according to the situation.
- Industrial chiller. An industrial chiller capable of satisfying a 15 kW induction heating plant costs around $400 to $600.
Buying on eBay or from China?
When you look at many induction forges from e-commerce sites like eBay, you will find that they almost have similar shapes. Yes, most induction heaters for forging come from China, although they use local brands. Various dealers simply changed the color and brand of the machine. One possible potential benefit of buying from eBay is that you may receive the machine sooner. Of course, sometimes you also need to wait for the dealer to import the machine from China.
It is also a good idea to buy Induction Forge from Chinese manufacturers and suppliers. You can directly get more professional technical support and after-sales support from Chinese manufacturers. What’s more, you can get the induction forging machine at an affordable factory price, and your cost is only to wait for 2 or 3 weeks.
How to choose a machine?
The power of the common small induction forge is 15 kW, and the maximum power exceeds 200 kW. If you’re going to be heating large billets, then you might even need a machine with over 1000 kW.
You can choose high frequency 15 kWh or 25 kW induction forge when you heat small metal parts, such as blades, sickles, kitchen knives, hoes, files, awls, scissors, drills, wrenches, etc.
If you are going to heat relatively large parts, such as steel bars or iron bars with a diameter of more than 20mm, then a medium frequency induction heating machine is more suitable. Its frequency is between 1 kHz and 10 kHz, and it can heat directly on the steel rod core, with better heat penetration and fast heating speed.
induction forge for steel bars
A 15 kW induction forging machine with all the necessary equipment costs between $930 and $1800. You can choose the machine according to the size of the part you want to heat. But before buying, please confirm with the dealer or manufacturer that the machine is suitable. Whether buying an induction forge on eBay or from China, be sure to check with the seller how soon you can expect to receive the machine.
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