INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6, pp.

903-909

JUNE 2013 / 903

DOI: 10.1007/s12541-013-0119-6

Reduction of Heat Losses for the In-line Induction

Heating System by Optimization of Thermal Insulation
Hong-Seok Park1,#

and

Xuan-Phuong Dang1

1 Laboratory for Production Engineering, School of Mechanical and Automotive Engineering, University of Ulsan, Korea, 680-749
# Corresponding Author / E-mail: phosk@ulsan.ac.kr, TEL: +82-52-259-1458, FAX: +82-52-259-1680
KEYWORDS: Thermal insulation, Induction heating, Energy-savings, Optimization

Improving the electrical energy efficiency of the manufacturing process is the imperative task to resolve the cost-saving pressure and
environmental legislations. This paper focuses on a study on the thermal efficiency of the in-line induction heating systems that are
using in the hot forging applications. Besides optimizing the process parameters that increase the electromagnetic and thermal
efficiency, reducing the heat losses to the surrounding air is one of the practical ways to save the operating energy. The weakness of
the current in-line induction heating systems were pointed out, and we proposed an insulating system to reduce the heat losses caused
by convection and radiation. The analytical model of the heat transfer and the simulation model were built to calculate and verify the
thermal efficiency of the insulating covers. The results show that using insulating covers at the open spaces between adjacent heaters
of an in-line induction heating for automotive crankshaft forging can approximately reduce 9% of heat losses compared with the
energy stored in the workpiece. The best values of the geometrical design parameters of the insulating cover were determined by
solving the constrained optimization that considers some technological aspects of the proposed insulating system. This work is intended
as a contribution to make the hot forging industry become greener and more efficient in terms of saving operating energy.
Manuscript received: October 2, 2012 / Accepted: February 17, 2013

NOMENCLATURE
= heat-transfer coefficient (W/m2oC)
= thermal conduction (W/moC)
= emissivity
= kinematic viscosity (m2/s)
= Stefan-Boltzmann constant (W/m2.K4)
q = heat transfer rate per unit length (W/m)
t = temperature (oC)
Gr = Grashof number
Nu = Nusselt number
Pr = Prandtl number
Ra = Raleigh number

1. Introduction
Energy-savings considerations in manufacturing processes have
been drawing a great attention to the researchers and manufacturers

KSPE and Springer 2013

because of the ecological issues, cost-saving pressure, and new

environmental legislations.1 Improvement of machining and process
efficiency for manufacturing is one of the promising solutions.2,3 For
hot forging industry, induction heating process has been considered as
a high productivity, repeatable quality, and green heating technology
compared to fuel-fired furnaces. This is the reason why induction
heating, a best available heating technology, is preferred in forging
manufacturing.4,5 Induction heating prior to hot forging requires a huge
amount of electrical energy for heating a steel workpiece with large
volume from the ambient temperature to approximately 1150 ~ 1250oC.
Therefore, the heat losses account for a great number, and the increase
in the thermal efficiency of the heating system significantly saves the
consumed energy.
Solutions for saving energy for industrial induction heating may
include the energy management, innovative components of induction
devices, energy recovery, and adaptive control.6 Diverse published
works devoted to optimization of induction heating,7-13 but most of
them focused on how to minimize the temperature deviation at the end
of the heating process. Studies on minimizing the energy consumption
for particular manufacturing processes have been still dimmed although

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INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6

the producers of induction heaters are trying to increase the efficiency

of their products. Besides the optimization of process parameters,
practical solution that reduces the heat losses caused by radiation and
convection is an efficient way for saving the energy consumption.14
However, the study of reducing heat losses in the induction heating line
has not been focused adequately. This work tried to analyze the heat
losses through radiation and convection in order to find the solution for
saving energy in the in-line induction heating system.

2. State of the Research

This work aims at increasing energy efficiency for a hot forging
production of the automotive crankshaft in which the reduction of
thermal losses from the heating system is one of the important targets. As
previously mentioned, induction heating step is the one that consumes a
great amount of energy compared with other stages in the forging
process. Therefore, reduction of heat loss in the induction heating system
will increase the energy efficiency of the whole forging line.
The in-line induction system consists of seven heaters (research
objective) for heating the round steel bars with 97 mm of diameter and
6000 mm long as shown in Fig. 1. The steel bar moves continuously
through the in-line heaters with a designated velocity according to the
cycle time of 25 seconds. In every cycle time, the heated steel bar is cut
into 460-mm-long workpiece by the hot shearing machine before
moving to the crankshaft forging die. The rating power of the heating
line is 4250 kW.
To increase the energy efficiency of the in-line induction heating,
optimization the heating parameters and reduction of thermal losses are
the two potential methods. The way of increasing the energy efficiency
by process parameter optimization have successfully studied.14 The
investigation of the real induction heating system was carried out, and

it was found that the heat losses caused by convection and radiation at
the open spaces where the heated billet exposes to the ambient air
account for a significant amount of energy. The Figure 2 illustrates the
diagram of energy flow in the induction heating process in which
radiation accounts for an important portion. Table 1 and Figure 3 shows
the thermal losses of an induction heating line with seven heaters as
shown in the Figure 1.14 The notation t1 in the Table 1 is the
temperature at the surface of the heated workpiece obtained by using
a pyrometer at seven open spaces in the heating line. The heat flux
caused by convection and radiation per unit length (qconv and qrad) are
estimated by popular heat transfer formulas. In the in-line induction
heating, because the induction heaters are connected one by one, and
there are open spaces between heaters, the losses caused by radiation
and convection are remarkable. The total heat losses at the open spaces
between the heaters account for 82.2 KW, equivalent to 9.4% of the
heat energy stored in the SCM440 steel workpiece with 460 mm when
heating from 25oC up to 1220oC. However, the forging companies
dont always pay much attention on this issue due to the lack of the
study of how to reduce these heat losses and how is the efficient of the
using the insulation covers. The task of this research focuses on the
previously mentioned problem. Furthermore, an optimum design of the
insulating system was proposed to reduce the heat loses with a
maximum efficiency.

3. Development of the Insulating Covers to Reduce Heat

Losses for the In-Line Induction Heating System
3.1 The proposed thermal insulating system
The real in-line induction heating system shows that the distance
between two adjacent heaters usually accounts for 30% of the heater
Table 1 Rate of heat transfer in the case of without insulating cover

Fig. 1 In-line induction heating of a long steel bar prior to hot forging

Fig. 2 The diagram of energy flow in the induction heating processes

qconv (W/m) qrad (W/m)

Position
t1 (C)
1
812
2894
15496
2
889
3,208
20,413
3
950
3,458
25,069
4
1030
3,786
32,326
5
1160
4,322
47,330
6
1200
4,488
52,851
7
1220
4,571
55,785
Sum of heat losses of seven positions (W/m)

qsum (W/m)
18,390
23,621
28,527
36,113
51,653
57,339
60,356
275,999

Fig. 3 The power of radiation and convection losses at the open spaces
between heaters without using the insulating covers

INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6

length because they need spaces for the roller supporting and
translating the hot and heavy steel bar continuously (see Fig. 1). At
these open spaces, the extreme hot billet (approximate 800 ~ 1220oC)
directly exposes to the ambient air. Due to the very high temperature
at the billet surface, the heat losses caused by radiation and convection
are considerable. To reduce these losses, the insulating covers at the
open spaces were proposed as shown in Figure 4.
Due to the high temperature of the billet, it is found that the special
materials that can withstand this temperature as shown in Fig. 5. In
addition, these materials have a good manufacturability with the
available large size and the ability that can be machined into the
required shape.

3.2 Mathematical model for calculating heat transfer

The insulating device is considered as the multi-layer cylindrical
wall, including an annulus cylindrical air gap, a ceramic tube, and a
thin stainless steel cover. In fact, there is an open space below the
insulating cover; however, this area accounts for a small portion.
Consequently, this open area is ignored, and the insulating device is
treated as perfect cylindrical walls. The schematic axisymmetric layout
of the insulating cover is illustrated in Fig. 6. In addition, other
assumptions were made:
- The steady-state working conditions exist,
- The ceramic insulating layer and the metal cover are isothermal,
- Air is an ideal gas.
The heat flux transfers through each layer of insulating cover is
conservative.
(1)
q = q12 = q24 = q4

JUNE 2013 / 905

where q12, q24 and q4 are the heat flux through the air layer, ceramic
and steel cover layers, and from the outmost cover to the ambient air,
respectively.

3.2.1 The heat transfer at the outside of the insulating cover

The total rate of heat loss from the outmost cover is:
q4 = q4conv + q4rad

(2)

where q4con and q4rad are the heat losses caused by convection and
radiation, respectively. q4 is the heat flux per unit length transfers from
the outmost of the insulating cover to the ambient air (natural
convection in the infinite space) and can be calculated by assuming that
the temperature t4 is known.
q4conv = d4 ( t4 t ) = 4 Nu ( t4 t )

(3)

where d4 is the diameter of the outer of the cover, t4 is the temperature

at the surface of the cover, and t is the temperature of ambient air as
shown in Fig. 6.
4 Nu
= -----------d4

(4)

and Nu is calculated by the formulas15

14

0.518 ( GrPr )
Nu = 0.36 + --------------------------------------------------9 16 4 9
[1 + (0.559 Pr ) ]

(5)

The Grashof number is calculated as:

3

g ( t4 t )d4
Gr = ---------------------------2
v
t 4 + t
1
- is the mean film temperature
where = --- and tf = -----------2
tf

(6)

The thermal properties of air are assumed to be constant and are

taken to be the values at the mean film temperature.
The heat loss caused by radiation is calculated as
4

q4rad = d4 ( T4 T )

Fig. 4 Proposed thermal insulating covers at the open spaces between

adjacent heaters

Fig. 5 The selected insulating materials

Fig. 6 Schematic axisymmetric layout of the insulating cover

(7)

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3.2.2 The heat transfer through the insulating cover

The relation between the temperature t2 and t4 can be identified by
the theory of heat conduction through the cylindrical walls (ceramic
layer and stainless steel cover) in the steady-state.
t2 t4
q24 = -------------------------------------------------d3
1
1 - d4
------------ ln ----- + ----------ln ----22 d2 23 d3

Then the rate of heat transfer per unit length between the cylindrical
billet enclosed in a concentric the ceramic tube by convection becomes
2
q = -----------e ( t1 t2 )
d
ln ----2d1

(8)

The heat transfer per unit length caused by conduction in the air gap
is calculated as

in which it is assumed that q24 = q4 is already obtained as shown in

Section 3.2.1. The meaning of notations in formula (8) is shown in the
nomenclature and Fig. 6.
Temperature distribution in the cylindrical wall is
di + 1
d
t = ti ( ti ti + 1 ) ln ---- ln ------- di di

3.2.3 The heat transfer through the air gap layer

To determine the relation between the temperatures t1 and t2 at the
billets surface and the inner side of insulating cover, respectively (see
Fig. 6), the equations of heat transfer in the air gap are figured out.
(10)

where qconv, qcond and qrad are the heat transfer due to convection,
conduction, and radiation, respectively.
The heat flux through the enclosure can be determined from
Q
---- = ( t1 t2 ) = Nu
--- ( t1 t2 )
A

(12)

The theory of heat transfer indicates that the air in cylindrical annuli
(enclosure) behaves like a fluid whose thermal conductivity is Nu as
the results of convection. The quantity Nu is called the effective or
apparent thermal conductivity of the cylindrical annuli or enclosure.
That is16

e = Nu or -----e = Nu
(13)

The calculation is started by assuming that the temperature inside

the ceramic cylinder is known (t2), and thus an average temperature
(t1 + t2)/2 is identified. The property of air is evaluated at this
temperature.
The recommended relation for convective thermal conductivity is16
14
e
Pr
( F Ra )1 4
----- = 0.386 ----------------------cyl
0.861 + Pr

(14)

where the geometric factor for concentric cylinders Fcyl is

4

[ln ( d2 d1 ) ]
Fcyl = -------------------------------------3 3 5
3 5 5
( d2 + d1 )

(15)

(17)

d1 [t1 t2 ]
q12 rad = ------------------------------1 d1 1
---- + ----- ---- 1
1 d2 2

(18)

where = 5.67*10-8 (W/m2.K4) is the Stefan-Boltzmann constant; 1

and 2 are the emissivity of the billet and ceramic, respectively.

3.3 Solution strategy for calculating the temperatures and the

rate of heat transfer
The known temperatures are t1 of the hot billet and the temperature
t of the ambient air. The rate heat transfer through the insulating cover
and the temperature distribution depend on the thermal properties of
insulating materials and their geometrical parameter (thickness or
diameter, see Fig. 6). The governing equation for determining the heat
transfer rate and the temperature is the energy balance as shown in
equation (1). From the equation (1), two equations can be derived as:

(11)

where is the characteristic length of the enclosure that is the gap or

the spacing between the hot billet and the ceramic cover
( d2 d1 )
= -----------------2

Q 21 Tq = ---- = -----------------d
L
ln ----2d1

(9)

where the subscripts i and i + 1 denote the inside and outside of a

cylindrical layer.

q12 = q12conv + q12cond + q12rad

(16)

q12 = q24

(19)

q24 = q4

(20)

and

All of the components in Eq. (19) and (20) are identified as shown
in Section 3.2.
Assuming that the thickness of the insulating layers are
predetermined, the system of two equations (19) and (20) can be used
to determine the temperature t2 and t4 (two equations, two unknown
variables). All of the components in Eq. (19) and (20) are identified as
shown in Section 3.2. Whenever t2 or t4 is known, the rate of heat
transfer (rate of heat losses) is obtained. Then, the heat losses in the
case of with and without insulating cover can be compared.
For each value of the thickness 1 and 2, the temperature t2 and t4
has a certain value. As the result, the value of heat transfer rate also
changes. Therefore, the optimum value of 1 and 2 that minimize the
heat losses through the cover in the design pace can be found.

4. Design Optimization
The optimization problem is minimizing the heat transferred
through the insulating cover to reduce the heat losses within some
constraints of design space of the input design parameters. The problem
is stated as follows:

INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6

Find 1 and 2 that

minimize q12
subject to:
q12 = q24
q24 = q4
t2 allowable temperature of ceramic
d1min d1 d1max
d2min d2 d2max
In this optimization problem, it is noted that the objective function
also be treated as a constraint due to the system of Eq. (19) and (20).
The input parameters (design variables) are 1, 2, t2 and t4. These
parameters change within their constraints during the optimization
process.
To facilitate the optimization process, the iSight optimization tool
was adopted. The optimization problem can also be solved by solver
tool of MS Excel. The optimization process for seven insulating covers
between seven induction heaters in the heating line is carried out. The
optimization results are shown in the Table 2. In this Table, t1 is the
temperature of the surface of the workpiece (input value); t2, t4 and q
are the considered outputs; 1 and 2 are design variables (thickness of
insulating covers).

JUNE 2013 / 907

illustrates the FEM model for radiation simulation between the billet
and the cylindrical ceramic tube. The 2D-thermal element PLANE55
was used. The radiosity method of ANSYS was adopted for radiation
analysis. The radiation boundary conditions are the inner surface of the
ceramic cover and the outer surface of the heated workpiece. The
temperature of the workpiece is fixed as the temperature due to
induction heating. The ambient air is 25oC. The input parameters are
shown in Table 3. Fig. 8 shows the simulation results for the cover at
the last position of the heating line (the 7th or the hottest position with
1220oC of the billet). The simulations for other positions were done as
the same manner.
The simulation result shows that the temperature t2 inside the
ceramic tube is 1206oC, lower than the analytical result 4oC. This
difference is acceptable because the convection and conduction in the
air gap are ignored. The numerical simulation result implies that the
analytical model is accurate and believable. As the result, the
optimization process and the results are adequate. The result in the Fig. 8
also shows that the temperature in the inner surface of ceramic cover

5. Simulation Verification
The analytical result was verified by the simulation using ANSYS
software. Due to the restriction of the combination of convection and
radiation in the closed closure, only radiating heat transfer through the
air gap between the hot billet and the inner face of the ceramic was
done. Radiation heat transfer is dominated in the air gap, so the
convection and conduction in the air gap can be ignored. Figure 7
Table 2 Temperature distribution, rate of heat transfer, and the
optimum thickness of insulating layers in the case of using covers
Pos.

t1 (oC)

t2 (oC)

t4 (oC)

q (W/m)

1 (m)

2 (m)

812

799.4

109.1

896.5

0.02

0.08

889

877.5

115.6

989.4

0.02

0.08

950

939.3

120.7

1,063.1

0.02

0.08

1,030

1,020.1

127.1

1,159.9

0.02

0.08

1,160

1,151.5

137.2

1,317.3

0.02

0.08

1,200

1,191.9

140.2

1,365.8

0.02

0.08

1,220

1,210.0

151.2

1,748.1

0.045

0.078

Sum of heat losses (W/m)

Fig. 7 The FEM model for radiation simulation between the billet and
the ceramic tube

8540.1

Table 3 The values of parameters for heat transfer simulation in the

insulating cover
Parameter
t
t1
t2
tair
2

Value
25
1220
1210
25
0.16

Unit
o
C
o
C
o
C
o
C
W/moC

Parameter
4
1
2
Pr air
4

Value
0.0378
0.79
0.9
0.701
0.0718

16.3

W/moC

air

0.000155

Unit
W/moC

W/m C
m2/s

Fig. 8 Simulation result of heat transfer (temperature distribution) by

radiation in the insulating cover
Table 4 Comparision of heat losses (kW) in two cases: without and
with insulating devices
Position
1
Without
5.52
insulation
With
0.27
insulation

7.09

8.56

10.83 15.50 17.20 18.11

82.8

0.30

0.32

0.35

2.6

0.40

0.41

0.52

Sum

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INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6

is very high; however, the temperature at the outmost surface of the

cover drops dramatically, from 1206oC down to approximate 151oC.
This effect results in a good insulation or an effective reduction of heat
losses.

6. Results and Discussions

The geometrical parameters of the insulating covers at different
positions were obtained by solving the optimization problem as
mentioned in Section 5. Changing the input parameter t1 and the
constraint for the temperature t2 as well as the geometrical constraints
for 1 and 2 of different insulating covers at different positions in the
heating line, the optimum values of the 1 , 2 and the rate of heat
transfer are obtained. The final result shows that using insulating
covers at seven open spaces reduces the heat losses from 9.4% down
to 0.3% (82.8 kW down to 2.6 kW, see Table 4) compared with the
energy stored in the workpiece (saving around 9.1%). The data in Tale
4 were obtained by calculating the radiation and convection energy per
unit time in two cases. In the first case, the hot billet is exposed directly
to the ambient air without insulating cover. The second case uses the
insulating covers with the dimensions and temperature obtained from
the optimization results in Section 4.
It can be found that the increase of the temperature t2 can reduce the
heat loss caused by radiation but affect the service life of the insulating
cover. In addition, the smaller 1 thickness results in the higher t2 and
the smaller heat losses. It is easy to conclude that increasing the
thickness 2 of the insulating ceramic layer, the heat losses will be
reduced. However, if the upper range of the t2 is intercepted due to the
safety of the insulating material, the thickness 2 may not reach its
upper range. The optimum value of 1 tends to converge to the lower
margin because the lower value of 1, the higher of t2 and lower heat
losses caused by radiation (see equation 18). This trend of 1 brings the
advantage for the insulating system because the smaller air gap protects
the heater against overheat compared to the insulating cover with the
big air gap 1.
It is clear that the insulating system is very effective for saving the
energy. It is also simple in terms of structure, low cost, easy to
manufacture and assembly. The insulating ceramic material which can
withstand up to 1300oC helps the cover work safely without cooling
circuit. A thin stainless steel for the outmost layer is chosen in order to
lower the emissivity and protect the oxidization process of the
insulating system.

without the insulating system). The cost for making the insulating
system is not high, and it can work without maintenance. Therefore,
this is an effective way for saving energy for the induction heating
system. The working environment for the worker is improved due to
the reduction of the radiation and temperature in the shop floor.
Instead of using the simulation-based optimization, the analytical
approach for minimizing the heat losses and optimizing the design
parameters of the insulating system was adopted. This method
significantly reduces the computing time and obtains a reliable solution
because of the solid foundation of the theory of the engineering heat
transfer. The simulation tool was applied to verify the analytical results.
The real insulating system will be manufactured, implemented and
tested at the forging factory. At that time, the temperature of the heated
workpiece will increase due to the heat losses reduction. Consequently,
it is necessary to adjust and apply the optimization the processing
parameters of the induction heating line. The holistic combination of
new optimum heating parameters and a proper insulating system will
be implemented.

ACKNOWLEDGEMENT
This work was supported by the Ministry of Knowledge Economy,
Korea, under the International Collaborative R & D Program hosted by
the Korea Institute of Industrial Technology.

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In summary, this paper practically studies on the heat losses

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