The Challenge
For over 35 years, Lincoln Park Die & Tool has provided quality forgings to the automotive, trucking, recreational and aerospace industries. Increased demand made it imperative for Lincoln to find a new furnace that could not only heat a wide range of forging sizes and deliver them to a press or hammer, but could increase overall throughput as well.
The Way They Were
Lincoln forging capability ranges from high volume production and near net shape to short runs and prototype work. The company frequently takes projects from initial prototype design to final production forging. Lincoln had four natural gas fired slot furnaces, one induction billet heating system, and five drop forge hammers permitting production of forgings weighing up to 125 pounds. The general procedure had been to load bar stock into a traditional gas fired furnace and then raise it up to forge temperature. Once billets were properly heated, operators moved them manually from the furnace to the forge hammers or press to attain final shape. Gas furnace warm-up, hold and set-up times had been non-productive, eating up 37.5% of a normal shift, and leaving only about five true productive hours. In contrast, an induction system requires minimal warm-up and hold time. A full eight hours of billets can be brought up to temperature and forged. This allows for a double benefit: (1) 60% additional production capability on large volume runs and (2) quicker short production runs.
The Decision
With the assistance of Detroit Edison, Lincoln opted for an additional induction heating system. The decision, initially complex, was easy once a complete analysis was made of the advantages induction heating offered. Lincoln purchased one 750 kW, 1kHz solid state generator fed via continuous drive pinch roll assembly with a set of heat station components. This system is capable of heating 2" to 3" diameter by 6" to 20" long carbon steel billets to 2,350ºF at a rate of 4,000 pounds per hour.
The Benefits
Lincoln recognized that induction heating offered multiple advantages which have since paid off:
Higher Production Rates
An induction system generates heat within the work piece rather than the
convection and radiation heating traditional natural gas and oil furnaces
provide. Since induction heating time is significantly shorter, increased
throughput and reduced labor costs are realized.
Fast Furnace Startup
Traditional furnaces have large amounts of refractory material which must reach
process temperatures before the load can reach similar temperatures. Furnaces
must stay on during lunch or breaks consuming energy during non-productive
times. But because induction heating provides fast system startup, it
eliminates the problem of wasted energy.
Reduced Labor Costs
While a furnace operator is needed to run either a traditional furnace or an
induction system, rack and special set-up charges are avoided with induction.
By spreading fixed labor charges across increased output, it is quickly seen
that labor cost per ton is less with induction. The savings can reach 50%.
Less Scale Formation
Scale formation on carbon steels is a function of the time a work piece is
exposed to elevated temperatures, (longer exposure means greater scale
build-up). Scale reduces the die life for which a set of dies are designed.
Induction heating has enabled Lincoln to extend die life 25% longer than that
achieved through traditional gas fired heating methods. That's because with
induction heating, billets are brought up to temperature quickly and conveyed
to the forge press minimizing scale formation to 1/4 to 1/2%. Traditional gas
furnaces heat all the billets at once and hold them at forge temperature for a
longer time. The result is scale formation in the 2 - 4% range.
Summary
By analyzing Lincoln's situation and needs, Detroit Edison helped a good customer improve efficiency of their operation, enhance product quality, and reduce labor requirements and operating costs. Lincoln made the right choice with induction heating and continues in its role as a premier industry supplier.
Return to Induction Based Heating
Lincoln Park Die & Tool turns to induction heating. Boosts annual throughput potential by 60%.
Roger Magnusson (right), owner, Lincoln Park Die & Tool agrees with Detroit Edison Account Executive Marino Burla that teaming with Detroit Edison proved that induction heating technology was the superior choice for their billet heating application.
The 750 kW induction heating system purchased allows billets to be heated in a fraction (4,000 pounds per hour) of the time required by traditional natural gas fired furnace technology.
This is a sample of the many different kinds of quality parts forged by Lincoln Park Die & Tool.
Billets heated by induction produce less scale and extend die life by 25%. Here the press operator is forging the red hot billet to achieve the final shape.
Let Detroit Edison's energy consultants answer your process energy questions.
Simply contact your Account Representative to learn how we can be a part of your team when industry changes pose a challenge for you.
