Optimization of the in-line induction heating process for hot forging in terms of saving operating energy

Improving the efficiency of the manufacturing process is one of the ways to resolve the ecological issues, cost-saving pressure, and new environmental legislations. This paper presents the study on the in-line induction heating process prior to hot forging of an automotive crankshaft in order to find the potential solutions for improving the energy efficiency. The heating strategy that divides the induction heating line into groups for flexible control and saving operating energy was introduced. Optimization of the operating parameters of the induction heating system, including voltages and frequencies, was done using design of experiment in conjunction with numerical simulation, approximation, and genetic algorithm optimization techniques. In addition, thermal insulation was proposed to reduce the heat losses. The research results show that the energy can be saved through process parameter optimization approximately 6%. Furthermore, if the insulating covers at the open spaces between adjacent heaters are used, roughly 4% of additional amount of the energy consumption can be reduced.