Induction Forging Solutions

We design and manufacture high-performance induction forging machines, providing efficient and safe induction heating solutions for shrink-fit assembly tasks. Our machines serve industries, maintenance, and repair shops worldwide. Since 2006, we have been delivering reliable standard and bespoke solutions tailored to meet diverse needs.

    Induction Forging & KEXIN Forging Machines

    Induction forging offers significant benefits in mass production, especially within the forging industry. By integrating induction heating directly into production lines, it eliminates the need for large furnaces, reducing space requirements and solving power supply issues. Unlike traditional methods, induction forging ensures cleaner and more controlled heating.

    Since 2006, KEXIN has been a leader in induction heating technology. We provide innovative solutions such as the 45KW High Frequency Induction Forging Machine. Our equipment delivers precise, energy-efficient heating, helping manufacturers improve production efficiency.

    Induction Forging

    What is Induction Forging?

    Induction forging is a heating process used to shape metal parts by applying heat through electromagnetic induction. In this process, an alternating current is passed through a coil, creating a magnetic field that induces eddy currents within the metal workpiece. These currents generate heat, rapidly raising the temperature of the metal. Typically, metals are heated to temperatures between 1,100 and 1,200°C (2,010 and 2,190°F), which increases their malleability and aids in their flow during forging.

    Once the metal has reached the desired temperature, it is forged into shape using a press or hammer. The process is highly efficient and allows for precise control over heating, ensuring that the material is ready for deformation with minimal energy loss.

    The Principal Process of Induction Forging

    Induction forging uses electromagnetic induction to generate heat in metal workpieces. In this non-contact method, an alternating current (AC) passes through a coil, creating a magnetic field. When a metal workpiece is placed within this field, the changing magnetic flux induces eddy currents in the metal. These currents produce heat through Joule heating, raising the temperature of the metal.

    For magnetic materials like steel (or other ferromagnetic alloys), heating occurs below the Curie Point — the temperature at which the material’s magnetic properties undergo a significant change. For example, steel has a Curie Point of around 1,410°F (770°C), making it highly responsive to induction heating. The depth of heating depends on the frequency of the alternating magnetic field and the material’s permeability, with materials like steel and its alloys, which possess high permeability, being ideal candidates for induction forging.

    WHAT IS INDUCTION HEAT TREATMENT

    The Benefits of Induction Forging

    Fast and Efficient Heating

    Induction forging uses electromagnetic induction to rapidly heat metal workpieces. Unlike traditional methods, such as gas-fired or resistance furnaces, which require long preheating cycles, induction heating provides on-demand heat, drastically reducing the overall heating time. This results in higher productivity and faster manufacturing processes.

    Process Controllability

    Unlike traditional gas furnaces, it eliminates the need for preheating cycles or controlled shutdowns. Heat is available instantly when required and can be switched off immediately during downstream interruptions, saving energy and reducing scaling or oxidation on components. This flexibility ensures minimal downtime and maximum operational efficiency.

    Precise Temperature Control

    Electromagnetic induction provides precise and localized heating, focusing only on the areas that need to be forged. This precise control ensures consistent heating, reducing the chances of overheating or underheating the material. Uniform temperature control also minimizes material distortion and ensures the final product meets stringent quality standards.

    Rapid Temperature Rise

    High power densities in induction heating systems enable metal workpieces to reach the required temperature extremely quickly. This rapid temperature rise minimizes scale formation, reduces surface defects, and prevents undesirable effects on the metal’s surface metallurgy, resulting in improved material quality.

    Energy Efficiency

    Induction forging is highly energy-efficient as it directly heats the workpiece, rather than the surrounding atmosphere or equipment. Traditional heating methods often lose energy by heating the furnace or the air, whereas induction heating concentrates energy only where it’s needed. This efficiency reduces operational costs and contributes to sustainable manufacturing practices.

    Uniform Heating and Process Consistency

    The induction heating process ensures even heat distribution throughout the metal workpiece, eliminating hotspots or uneven temperature zones. This uniformity improves the accuracy of forging, reduces post-forging machining requirements, and enhances die life by preventing localized wear or stress on forging tools.

    No Harmful Byproducts

    Induction forging is a clean and environmentally friendly process. Unlike traditional methods, it produces no harmful emissions, such as smoke, toxic gases, or other waste products. Additionally, the shorter heating times reduce oxidation and scale formation, further enhancing the surface quality of the metal while lowering the need for additional treatments.

    Versatility of Induction Forging Across Industries

    Induction forging of steel knife

    Induction forging of steel knife

    Induction forging of wrench tools

    Induction forging of wrench tools

    Induction forging of steel shafts

    Induction forging of steel shafts

    Gear Forging by Induction machine

    Gear Forging by Induction machine

    Induction forging of gear teeth

    Induction forging of gear teeth

    Induction Iron Rods Forging

    Induction Iron Rods Forging

    Induction Iron Rods Forging
    Induction Iron Rods Forging

    Materials Suitable for Induction Forging

    • Steel and Stainless Steel
    • Aluminum and Aluminum Alloys
    • Copper and Copper Alloys
    • Brass
    • Titanium
    • Nickel-Based Alloys

    Industries of Induction Forging

    Induction forging has become an integral process in modern manufacturing, offering clean, fast, and energy-efficient solutions across various industries.

    Dies & Molds Industry

    Dies & Molds Industry

    Induction forging is widely used in the production and maintenance of dies and molds, replacing traditional steam, gas, or resistive heating methods. Its ability to deliver rapid and precise heating makes it ideal for this industry. Induction forging ensures faster production cycles, reduced energy consumption, and cleaner operations.

    Foundries and Metalworking Industry

    In foundries and casting facilities, induction forging is the preferred choice for its safe, energy-efficient, and environmentally friendly process. It is particularly effective in the metalworking and heat-treating industries, delivering quick, repeatable results for critical applications. Its ability to achieve uniform and controlled heating enhances the quality and durability of finished metal products.

    Manufacturing & Automation Fields

    Manufacturing & Automation Fields

    Induction forging encompass a wide variety of products and processes. Its adaptability makes it suitable for fully automated production lines that require high productivity, precision, and repeatability. Induction forging integrates with automated systems, streamlining operations and meeting the demands of modern manufacturing for efficiency and scalability.

    FAQS

    01.Why should I buy an induction forging machine?

    Induction forging machines provide unparalleled efficiency, safety, cleanliness, and accurate control. These machines offer the fastest method for hardening and heat treating metals, resulting in minimal distortion and a fine-grain microstructure. Induction heating is rapid, energy-efficient, and repeatable, making it ideal for precise or repetitive operations. Additionally, it is a flameless method, ensuring a safer and cleaner working environment.

    02.What are the advantages of an induction forging machine?

    • No case decarburization or formation of coarse grains.
    • Reduced scaling due to short heat-up times.
    • Extended service life of forging dies.
    • Fewer rejects caused by even and precise temperature control.
    • Immediate operational readiness with short setup times.

    03.How do I choose the right frequency for an induction forging machine?

    The required frequency depends on the material, size, and shape of the workpiece. For optimal recommendations, please send us an inquiry, and we will help you choose the most suitable machine based on your needs.

    04.How do I select the cooling system for an induction forging machine?

    The cooling system depends on your forging requirements. We will recommend the most suitable cooling solution for your specific application, ensuring the machine operates efficiently and reliably.

    05.Do I need to buy a cooling system separately for a KEXIN induction forging machine?

    Yes, a cooling system is required. You can either prepare a water tank and a water pump or opt for a cooling chiller to ensure efficient heat dissipation during machine operation.

    06.How long is the warranty period for KEXIN induction forging machines?

    We offer a one-year warranty for our machines. In case of any issues, you can send us videos or photos, and our engineers will analyze the problem. We will provide spare parts for replacement and offer life-long technical support and additional assistance.

    07.Can induction forging machines be used for automated production lines?

    Yes, induction forging machines are ideal for integration into automated production lines. Their precise temperature control, fast heating capabilities, and repeatability make them perfect for high-productivity, automated manufacturing processes.

    08.How does induction forging save energy compared to traditional methods?

    Induction forging directly heats the workpiece, reducing heat loss to the surrounding environment. Unlike gas or resistance furnaces, induction forging focuses energy only where it is needed, resulting in significant energy savings and lower operational costs.

    09.Is induction forging environmentally friendly?

    Yes, induction forging is an environmentally friendly process. It does not produce harmful byproducts like smoke, fumes, or toxic gases, and it minimizes oxidation and scale formation on the workpiece. This makes it a cleaner and safer option for both operators and the environment.

    10. How long does it take for an induction forging machine to heat the material?

    Induction forging machines heat materials very quickly, often within seconds, depending on the size and type of the workpiece. This rapid heating capability improves productivity and reduces cycle times compared to traditional heating methods.

    11. Can induction forging machines handle irregularly shaped workpieces?

    Yes, induction forging machines can be customized to handle a variety of shapes and sizes. By adjusting the induction coil design, the machine can heat irregularly shaped workpieces uniformly and efficiently.

    12. What are the safety features of KEXIN induction forging machines?

    KEXIN machines are designed with advanced safety features, including overheating protection, automatic shutdown systems, and precise temperature controls. Additionally, the absence of open flames ensures a safer working environment for operators.

    13. How do I maintain an induction forging machine?

    Regular maintenance involves checking the cooling system, cleaning the induction coils, and ensuring proper electrical connections. We provide maintenance guidelines and life-long technical support to ensure your machine operates efficiently for years to come.

    14. Can induction forging machines improve the lifespan of forging dies?

    Yes, the precise and uniform heating provided by induction forging reduces wear and tear on forging dies. This controlled heating minimizes localized stress and scaling, significantly extending the die’s service life.

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