PROFESSOR INDUCTION
by Valery I. Rudnev • Inductoheat Group
Electromagnetic forces
Professor Induction welcomes
comments, questions, and
suggestions for future columns.
in induction heating
Since 1993, Dr. Valery Rudnev
has been on the staff of
Inductoheat Group, where he
currently serves as group
those forces can physically move the
E lectromagnetic (EM) forces play the
major part in many modern tech-
nologies.1 Motors, magnetohydrody-
heated workpiece or flux concentrator,
and even bend the induction coil or
director – science and
technology. In the past, he was an associate
professor at several universities, where he
namic (MHD) seals, electromagnetic fixture, which may negatively affect taught graduate and postgraduate courses.
pumps, levitators, electrical bearings, overall system reliability and re- His expertise is in materials science, heat treating,
and springs are some of the modern peatability, as well as dramatically re- applied electromagnetics, computer modeling, and
technologies in which EM forces play duce coil life. process development. He has 28 years of
a leading role. In some applications, Unfortunately, electromagnetic experience in induction heating.
EM forces can reach tremendous forces are rarely discussed in induc- Credits include 16 patents and 128 scientific
values. For example, thanks to a ca- tion heating publications. Each of the and engineering publications.
pability to develop incredibly large seemingly endless variety of heat
electromagnetic forces, electric guns treated parts requires a specific coil Contact Dr. Rudnev at Inductoheat Group
geometry (Fig. 1), which makes it dif- 32251 North Avis Drive
or launchers can fire materials to
Madison Heights, MI 48071
higher velocities than are achievable ficult to study EM forces. This column
tel: 248/585-9393; fax: 248/589-1062
by rockets or chemical/powder guns.2 is intended to at least partially remedy
e-mail: rudnev@inductoheat.com
In the majority of induction heating this by providing an introduction to
Web: www.inductoheat.com
applications, coil current also can the topic.
reach appreciable values. For example,
currents of 10 kA and higher are not How EM Forces Form
unusual for many induction heat A current-carrying conductor
treating applications, including shaft placed in a magnetic field experiences
hardening and gear hardening. High a force that is proportional to current
currents produce significant forces and magnetic flux density.1 Thanks to
that have a pronounced effect on coil a study by Ampere and Biot-Savart,
life. Without proper consideration, this force can be quantified. If current-
Fig. 1 — Inductors for hardening complex-shaped parts. Photo courtesy Inductoheat Inc.
HEAT TREATING PROGRESS • JULY 2005 25
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PROFESSOR INDUCTION
carrying element dl, carrying a current to bring the conductors together. They
I, is placed in an external magnetic will experience an attractive force, F12
field B, it will experience a force dF ac- = F21. In some cases, the forces are so
cording to: large that they can deform bus bars.
What follows are simplified calcu-
Conductor dF = I x Bdl = IBdlsinφ Eq. 1 lations of attractive magnetic forces
element
occurring between two thin wires,
F, I, and B are vectors and φ is the each carrying a current of 200 A and
angle between the direction of the cur- separated by a distance of 20 mm (0.8
rent I and magnetic flux density B. in.). According to basic electromag-
In SI units, the force is measured in netics, each of the parallel current-car-
Fig. 2 — Left hand rule (FBL rule) of mag- newtons (1 N = 0.102 kgf = 0.225 lbf). rying wires produces a magnetic field
netic force. F = electromagnetic force. B = mag- Figure 2 shows that the direction of according to the equation:3
netic flux density. I = current. dl = element of the force experienced by the element
current-carrying conductor. (Ref. 1) dl of the current-carrying conductor B = µ0I/2πR Eq. 2
placed in an external magnetic field B
can be determined based on the left R is the radial distance between the
hand rule (FBL rule). According to the wires (Fig. 4). Therefore, the magnetic
rule, if the middle finger of the left force experienced by the second wire,
hand follows the direction of current according to Eq. 1, will be:
flow and the pointer finger follows the
F = I2(µ0I1/2πR)l, and the force per
direction of the magnetic flux of the
external field (magnetic field lines unit length will be F/l = I2 (µ0I1/2πR)
head into the palm), then the thumb In this case, the force per unit length
will show the direction of the force. will be:
It is important to remember from F/l = [4π × 10–7 Wb/(A × m)(200 A)2]
Eq. 1 that, if the angle φ between the /2π(0.02 m) = 0.4 N/m
direction of the current I and magnetic
field B is equal to zero, then sin φ = 0 Multiturn coils: These phenomena
and, therefore, no force will be experi- can also be applied to a multiturn so-
enced by the current-carrying con- lenoid inductor (Fig. 5). Alternating
Fig. 3 — Magnetic forces in current-car- ductor. In other words, if the current- voltage applied to a multiturn sole-
rying conductors (labeled 1 and 2). When cur- carrying conductor is parallel to an noid results in a current flow within
rents flow in opposite directions, top, the elec- external magnetic field, then it will not it, producing electromagnetic forces.
tromagnetic forces attempt to push the experience any force from that field. Since the currents flowing in each turn
conductors apart. When currents flow in the The lesson here is that magnetic force
same direction, bottom, the EM forces try to
of the multiturn solenoid are oriented
depends upon orientation of the cur- in the same direction, the turns will
squeeze them together. (Ref. 1) rent-carrying conductors, among other experience longitudinal compressive
factors. stresses. Assuming an infinitely long
solenoid and a homogeneous mag-
How Heat Treating Is Affected netic field, it can be shown that the
But what does EM force mean to in- longitudinal magnetic pressure (den-
duction heat treaters? Consider these sity of the magnetic force in N/m2) fl
common cases of magnetic forces in inside the long and homogeneous so-
induction heating applications.1 lenoid can be expressed as:
Push apart: If two current-carrying
conductors (such as bus bars or cables) fl = Fl/Area = µ0Ht2/2 = Bt2/(2µ0) Eq. 3
having currents flowing in opposite
directions are located near each other, In the case of the infinitely long
then each conductor will experience multiturn solenoid, Ht is the root mean
Fig. 4 — The magnetic interaction between
two thin current-carrying wires. The currents forces oriented in the opposite direc- square (rms) tangential component of
(I) are flowing in the same direction. F is the tion (Fig. 3, top), which are attempting vector H (magnetic field intensity).
EM force. R is the distance between the wires. to separate the conductors, F12 = –F21.
Ht = NI/l Eq. 4
Squeeze together: In contrast, if
two conductors are carrying currents N is the number of turns in the long
oriented in the same direction (Fig. 3, solenoid of length l, and I is the coil
bottom), the resultant forces will try current.
26 HEAT TREATING PROGRESS • JULY 2005
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PROFESSOR INDUCTION
Forces produced when induction heating a 50 mm (2 in.) OD steel shaft, N (lbf)*
Force component Temperature below Curie point Temperature above Curie point
Fhoop 81 (18.2) 298 (67)
Flongitudinal 443 (99.6) 928 (209)
Fradial 1.4 (0.3) 5.2 (1.2)
* Two-turn induction coil, 189 kW power, 1 kHz.
unequal distribution of electromag- Imagine a situation where two adult excessive vibration, and too much
netic forces into account. Numerical men, each weighing 95 kg (209 lb), are noise. However, in other applications,
computer modeling can provide ap- hanging on each turn of the two-turn those forces can be desirable and play
preciable help when evaluating them. coil trying to pull it apart. Obviously, an important role in the process; for
An example, given in Fig. 7, shows the such intensive force cannot be ne- example, the electromagnetic stirring
magnetic field distribution around a glected since it dramatically affects coil effect in an induction melting
two-turn induction coil for hardening life, and should be properly taken into furnace.
a 2 in. (50 mm) OD shaft using a consideration when designing induc-
power/frequency combination of 180 tion heating systems. Thus, a special References
kW/1 kHz. effort should be made to improve coil 1. Handbook of Induction Heating, by V.
The table lists the magnetic forces design, which will help reduce elec- Rudnev, D. Loveless, R. Cook, and M. Black:
produced when this carbon steel shaft tromagnetic forces and make the Marcel Dekker Inc., New York, 2003, 800 p.
2. “UK electric gun national overview,”
is heated to temperatures below and overall system more robust.
by D. Haugh and M. Firth: IEEE Transac-
above the Curie temperature. Conclusion: Depending upon the
tions on Magnetics, Vol. 37, No. 1, January
When heating above the Curie tem- application, magnetic forces can ad- 2001, p. 33–36.
perature, each turn of the two-turn coil versely affect the rigidity and re- 3. Electromagnetism for Engineers, by P.
will experience the maximum longi- peatability of an induction heating Hammond: Pergamon Press, New York,
tudinal force of 928 N (209 lbf). system, causing premature coil failure, 1978, 248 p.