Induction Heating and Electromagnetic Metal Forming for Advanced Processing Technologies

Induction Heating and Electromagnetic Metal Forming for Advanced Processing Technologies presents a rigorous and practically oriented study of two highly promising directions in modern manufacturing science: non-contact induction heating of conductive materials and magnetic-pulsed deformation of sheet metals. The monograph is written by Professor Yuriy Batygin, a distinguished Ukrainian scholar whose research is closely associated with electrophysical processes, induction systems, magnetic-pulse technologies, and applied electrodynamics. The publication begins with a broad scientific and technological introduction to induction heating and electromagnetic metal forming, showing how electromagnetic field energy can be used for force action, local heating, and improvement of manufacturing and repair operations. Particular attention is given to the combination of magnetic-pulse processing with preliminary induction heating, where increased metal plasticity can improve the quality of deformation while reducing the required force amplitudes and energy consumption. A major strength of this monograph is its systematic analysis of induction heating as an industrial and repair technology. The author examines the physical nature of eddy-current heating, the role of skin effect, proximity effect, magnetic permeability, and electromagnetic coupling, and then moves to practical questions of equipment design and application. The historical development of induction heating is also traced from its early theoretical foundations to modern uses in manufacturing, transport engineering, and vehicle repair. Another essential contribution of the monograph is its detailed treatment of magnetic-pulsed attraction of sheet metals. In contrast to traditional electromagnetic forming, which is usually based on repulsive Lorentz forces, this work studies systems in which attraction can be achieved and controlled. The author reviews the known approaches based on superposition of high and low frequencies, analyzes low-frequency attraction of ferromagnetic materials, and presents less widely known developments protected by Ukrainian patents. The theoretical core of the book is formed by the chapters devoted to flat solenoids with ferromagnetic cores and to systems with “current direct passage” through the processed metal. Here the author develops the physical and mathematical foundations of electromagnetic interaction in the system “inductor–heating object,” considers massive and thin-walled metal specimens, and analyzes the effects of real conductivity, idealized transparency, and field penetration. Special emphasis is placed on the use of ferromagnetic inserts, which significantly increase the amplitudes of excited magnetic fields and intensify induction heating. The monograph then advances to a new technical concept: magnetic-pulsed attraction with direct current passage, where the interaction of conductors connected to an external power source replaces the conventional force interaction between tool field and induced current. This is one of the book’s most original engineering ideas. The practical value of the monograph is reinforced by an extensive experimental section. The book reports experimental studies of induction heating using tools with ferromagnetic cores and magnetic-pulsed attraction under current direct passage conditions. According to the presented results, the introduction of ferrite cores more than doubles the amplitudes of induced eddy currents and increases the heating rate of thin sheet metals by more than three times. Experimental measurements of field distribution and force action show good agreement with theoretical estimates and confirm the feasibility of controlled, dosed deformation in sheet-metal processing zones.