3D Multiphysics modelling applied to parametric analysis on inductors design

The inductors design process is the key point in the development of an induction heating machine to fulfill the customer specifications. Some special hardening profiles can be uniquely achieved using the induction heating technology. Different inductors shapes, flux concentrators, power supply frequencies and cooling media can be used to get the optimal thermal profile for the heat treatment.The possibility to study the design robustness of the process using virtual prototyping is the key to speed up the test-trials loop and to give a tool for a better understanding of the process.In the paper it is presented a case study applied to a real industrial problem. A batch of FEM (finite element method) simulations has been done to find the key parameters in the element positioning tolerances, the effect of the misalignment, and the influences of the part geometrical tolerances. Some additional simulation runs have been made to optimize the inductor shape to stiffen the system and perform a more stable process.The method used is based on the FEM taking in to account the coupling between the electromagnetic and thermal fields, and the nonlinear behavior of the material properties.