紧凑式辊底式连续热处理炉优化加热控制策略

以某公司辊底式连续热处理炉为研究对象,在详细分析其传热机理的基础上,建立了钢坯在炉内加热过程的数学模型,针对该炉型具有的紧凑、主要生产宽厚板、工艺复杂和混装现象严重等特点,提出了紧凑式宽厚板辊底式热处理炉连续和摆动优化加热控制策略.其中包括：钢坯运行控制策略、加热保温控制策略及其不同工艺不同规格钢坯的混装优化控制策略.运行控制策略涉及连续运行策略及摆动运行策略;加热保温控制策略涉及炉温优化设定、钢坯在炉加热保温时间设定及辊速设定;混装控制策略涉及炉温的动态叠加优化设定等.所开发的控制策略已成功地应用于某公司的辊底式连续热处理炉计算机优化控制系统中,取得了令人满意的控制效果.     

Solving hyperbolic heat conduction using electrical simulation

In the present study, the electrical network simulation method is proposed to solve the hyperbolic and parabolic heat conduction problem considering Cattaneo-Vernoute (C.V) constitutive relation. Using this new proposed numerical model and the electrical circuit simulation program HSPICE, transient temperature and heat flux profiles at slab can be obtained easily and quickly. To verify the proposed method, the obtained numerical results for cases of one dimensional two-layer slab under periodic boundary temperature with perfect and imperfect thermal contact are compared with the published results. Comparisons show the proposed technique might be considered as a useful tool in the analysis of parabolic and hyperbolic thermal problems.     

Experimental and numerical studies on the thermal analysis of the plate in indirectly fired continuous heat treatment furnace

Experimental and numerical studies were performed by considering convective and radiative heat transfer to predict the transient thermal behavior of a plate in an indirectly fired continuous heat treatment furnace. The temperature profiles in the plate were determined by solving the transient one-dimensional heat conduction equation in conjunction with appropriate boundary conditions by using a time marching scheme. The results obtained from the transient analysis were substantiated by comparing with experimental results. Additionally, parametric investigations were performed to examine how the thermal behavior of the plate is affected by plate and refractory emissivities, charging temperature and residence time of the plate, gas temperature of the work and drive sides of the heat treatment furnace, and plate thickness. This paper was recommended for publication in revised form by Associate Editor Ohchae Kwon Young-Deuk Kim is a graduate student at Hanyang University in Seoul, Korea. He earned his B.S. in Mechanical Engineering from Korea Maritime University in 2002 and his M.S. in mechanical engineering from Hanyang university in 2004. His current research areas are modeling of automotive aftertreatment catalysts, optimal design of thermal systems, and phase change modeling with free surface flow. Deok-Hong Kang is a senior researcher at the RIST (Research Institute of Industrial Science and Technology) in Pohang, Korea. He earned his B.S. and M.S. in mechanical engineering from Hanyang University in 1989 and 1993, respectively, and his Ph.D. in mechanical engineering from POSTECH in 2004. His current research areas are mathematical modeling for combustion control, furnace optimization control system, and energy saving engineering in all kinds of furnaces. Woo-Seung Kim is a professor in mechanical engineering at Hanyang University in Ansan, Korea. He earned his B.S. in Mechanical Engineering in 1981 from Hanyang University and his M.S. and Ph.D. in mechanical engineering from North Carolina State University in 1986 and 1989, respectively. His current research areas are modeling of automotive aftertreatment systems, inverse heat transfer problems, optimal design of thermal systems, and phase change heat transfer problems with free surface flow.     

Improved 3-omega measurement of thermal conductivity in liquid, gases, and powders using a metal-coated optical fiber

A novel 3ω thermal conductivity measurement technique called metal-coated 3ω is introduced for use with liquids, gases, powders, and aerogels. This technique employs a micron-scale metal-coated glass fiber as a heater/thermometer that is suspended within the sample. Metal-coated 3ω exceeds alternate 3ω based fluid sensing techniques in a number of key metrics enabling rapid measurements of small samples of materials with very low thermal effusivity (gases), using smaller temperature oscillations with lower parasitic conduction losses. Its advantages relative to existing fluid measurement techniques, including transient hot-wire, steady-state methods, and solid-wire 3ω are discussed. A generalized n-layer concentric cylindrical periodic heating solution that accounts for thermal boundary resistance is presented. Improved sensitivity to boundary conductance is recognized through this model. Metal-coated 3ω was successfully validated through a benchmark study of gases and liquids spanning two-orders of magnitude in thermal conductivity.     

Steel billet reheat simulation with growth of oxide layer and investigation on zone temperature sensitivity

This paper presents a three-dimensional heat conduction numerical model and simulation of steel billet reheating in a reheat furnace. The model considers the growth of oxide scale on the billet surfaces. Control-volume approach and implicit scheme of finite difference method are used to discretize the transient heat conduction equation. The model is validated with analytical results subject to limited conditions. Simulations are carried out for predictions of three-dimensional temperature filed in the billet and oxide scale growth on the billet surfaces. The model predictions are in agreement with expected trends. It was found that the effect of oxide scale on billet heating is considerable. In order to investigate the effect of zone temperatures on the responses, a parametric sensitivity subject to six responses of interest are carried out using analysis of mean approach. The simulation approach and parametric study presented will be useful and applicable to the steel industry.     

Effect of spatial variation of thermal conductivity on non-fourier heat conduction in a finite slab

The non-Fourier heat conduction problem in a finite slab is studied analytically. Dependence of thermal conductivity on space has been considered. The Laplace transform method is used to remove the time-dependent terms in the governing equation and the boundary conditions. The hyperbolic heat conduction (HHC) equation has been solved by employing trial solution method and collocation optimization criterion. Results show that the space-dependent thermal conductivity strongly affects the temperature distribution. A temperature peak on the insulated wall of the slab has been observed due to linear variation of thermal conductivity. It has been shown that the magnitude of the temperature peak increases with increasing the dimensionless relaxation time. To validate the approach, the results have been compared with the analytical solution obtained for a special case which shows a good agreement.     

The influence of tube and membrane structure on dynamic instability in furnace wall tubes of a fossil fired once-through boiler in a simulated furnace environment

A numerical model was developed to investigate dynamic instability in fossil fired once through boilers and the influence of the dynamics of tube and membrane structure furnace wall tubes on the stability boundary was examined. In order to predict density wave oscillation (DWO), the most common type of dynamic instability, a time domain nonlinear analysis approach was used to give a transient flow field in the tubes. The tubes were divided into one-dimensional finite volumes along their lengths and equations of conservation of mass, momentum and energy were discretized to give algebraic equations. The SIMPLE algorithm was adopted to solve these equations. Analysis of two-dimensional transient conduction across a tube-membrane section of each volume was performed concurrently and the resulting heat transfer between tube inner wall and fluid was included in the source term of the energy equation. After verification with results in available literature, the model was applied to a wall tube section of a 700 MW boiler furnace in subcritical once-through condition. The stability boundaries for three types of tube configuration were predicted, and it was found that the dynamics of tube configuration can have a significant effect on the flow instability in the boiler furnace wall tubes.     

A Vacuum High-Temperature Electric Furnace for Investigating Thermal Properties of Materials

A vacuum electric furnace for investigating thermal properties of materials at temperatures of up to 2500°C was developed and tested. The furnace allows experimental studies of the heat conduction of both liquid and solid materials and measurements of the temperature and heat of phase transitions. It can be used to smelt and cake metals and alloys in vacuum or in an inert-gas medium. The heater is made of a graphite tube with special slots for increasing its resistance. The electric power is supplied from an ОСУ-40 step-down transformer. The temperature in the heated zone is controlled and monitored with an РТЭ-4.1 digital temperature controller connected to a computer. The power consumed by the furnace is no higher than 20 kW, and the volume of the working chamber is 0.3 L. The time for reaching the maximum temperature is at most 30 min.     

Transient response of a thermoelectric generator subjected to spatially non-uniform heating: Implications for heat and IR sensing applications

We present a combined experimental and computational investigation of the transient behavior of a thermoelectric generator (TEG) subjected to temperature gradients of less than 0.5 K across its thickness. Such conditions can exist when TEGs are used as heat sensors or IR detectors. Spatially non-uniform heating was initiated by allowing light to strike the central portion of one side of the TEG or by placing a small heated probe in contact with that surface. The time-dependent, open circuit voltage output of the TEG was predicted using temperature results from a three dimensional transient heat conduction finite element model. It is shown that the transient voltage output is influenced by the configuration of the mounting hardware, by the thermal properties of the TEG’s materials of construction, and by convection. Three-dimensional heat conduction in the TEG determines the nature of the transient voltage output, which, in some cases, exhibits an overshoot.     

基于温度场的磨齿热特性研究

根据七轴五联动螺旋锥齿轮磨齿机的结构模型和数控磨削原理,采用热传导和矩形移动热源理论及有限元分析方法,建立了磨齿温度场有限元分析3D模型和磨齿瞬态温度场。由此,对热和结构两个物理场进行耦合,仿真分析了磨齿瞬态热特性。实例分析表明,磨齿瞬态最高温度远高于磨齿稳态温度,且位于磨削弧中心;其它各点的瞬态温度,随位置、时间以及其它影响因素的不同,呈现不同的变化规律。磨齿瞬态热应力、热变形与磨齿瞬态温度密切相关,同时还受结构、材料特性和磨削条件等因素影响,磨齿瞬态最大热应力与热变形位于磨齿瞬态最高温度附近。在其它条件相同时,采用油基磨削液的瞬态最高温度、热应力与热变形均比采用水基磨削液时要大。这些研究为控制螺旋锥齿轮磨削质量以及磨齿热变形的修形提供了依据。     

Effects of rolling parameters on work-roll temperature distribution in the hot rolling of steels

Temperature variations of work-rolls in the process of hot rolling of slabs were analyzed by solving heat conduction equation with time-dependent boundary conditions. The Raylieght-Ritz and the finite-element methods were employed to solve the governing equation. To improve the accuracy, the thermal relationship between rolling metal and work-rolls was taken into account as well as the effects of different parameters such as interface heat transfer coefficient, rolling speed, and slab initial temperature were considered in the calculations. To verify the employed model, a comparison was made between the predicted and the recorded time-temperature history and good agreement was observed. Modelling results show that the interface heat transfer coefficient and rolling speed are important factors that vary effectively the temperature field within the work-roll. In addition, the interface heat transfer coefficient is affected by the other parameters and factors such as flow stress behavior of the metal being rolled and initial temperature of metal. Therefore, in order to determine an accurate temperature field within the work-rolls, flow behavior and temperature distribution in the rolling metal should also be calculated at the same time.     

滚动轴承打滑蹭伤试验研究

基于高速滚动轴承试验机对滚动轴承打滑蹭伤展开试验研究,获得不同工况参数下滚动轴承打滑蹭伤的临界转速;研究滚动轴承在打滑蹭伤临界转速下不同运行时间对滚动轴承磨损程度的影响,以及滚动轴承打滑蹭伤后,继续以更高转速运行对滚动轴承磨损程度的影响。结果表明:滚动轴承发生打滑蹭伤瞬间伴随着摩擦扭矩、温度及振动加速度的同步突增,且其在润滑不充分及轻载工况下出现打滑蹭伤时的临界转速更低;滚动轴承在打滑蹭伤临界转速下运转时间越长,磨损越严重,这可能是由于打滑蹭伤破坏滚动轴承表面光洁度,使摩擦因数增大从而导致磨损速度加快;滚动轴承打滑蹭伤后,继续以更高转速运转时易出现二次淬火烧伤,大大降低轴承使用寿命。     

螺旋锥齿轮磨齿温度场研究与应用分析

根据螺旋锥齿轮的数控磨削原理,采用热传导和矩形移动热源理论及有限元分析方法,建立了磨齿温度场有限元分析3D模型和磨齿瞬态温度场。对热和结构两个物理场进行耦合,仿真分析了磨齿瞬态热应力和热变形。实例和试验分析表明:磨齿瞬态最高温度远高于磨齿稳态温度,且位于磨削弧中心;其他各点的瞬态温度,随位置、时间以及其他影响因素的不同,呈现不同的变化规律。磨齿瞬态热应力、热变形与磨齿瞬态温度密切相关,同时还受结构、材料特性和磨削条件等因素的影响,磨齿瞬态最大热应力与热变形位于磨齿瞬态最高温度附近。在其他条件相同时,采用油基磨削液的瞬态最高温度、热应力与热变形均比采用水基磨削液时要大。     

Heat transfer simulation and thermal measurements of microfabricated x-ray transparent heater stages

A microfabricated amorphous silicon nitride membrane-based nanocalorimeter is proposed to be suitable for an x-ray transparent sample platform with low power heating and built-in temperature sensing. In this work, thermal characterization in both air and vacuum are analyzed experimentally and via simulation. Infrared microscopy and thermoreflectance microscopy are used for thermal imaging of the sample area in air. While a reasonably large isothermal area is found on the sample area, the temperature homogeneity of the entire sample area is low, limiting use of the device as a heater stage in air or other gases. A simulation model that includes conduction, as well as radiation and convection heat loss, is presented with radiation and convection parameters determined experimentally. Simulated temperature distributions show that the homogeneity can be improved by using a thicker thermal conduction layer or reducing the pressure of the gas in the environment but neither are good solutions for the proposed use. A new simple design that has improved temperature homogeneity and a larger isothermal area while maintaining a thin thermal conduction layer is proposed and fabricated. This new design enables applications in transmission x-ray microscopes and spectroscopy setups at atmospheric pressure.     

转化法分析气体中的总硫含量仪器的研制

采用加氢转化炉,使气体中的硫化物在一定的温度条件下转化成硫化氢,用几种硫化物做转化率实验,根据这些数据说明可以用转化法较为简单地分析气体中的总硫.采用专门的自制色谱柱对硫化氢进行分离,用火焰光度检测器进行检测.在不使用转化炉时,可以随时装卸转化炉,维护方便,单独的微量硫分析仪还可以测其形态硫,使用较为灵活.仪器具有很高的可靠性和稳定性,检测限能达到0.05×10-6或0.02×10-6(以硫化氢计).     

湿式摩擦离合器摩擦片油槽对瞬态传热的影响

计算了湿式摩擦离合器摩擦片的热流密度和对流换热系数,建立了考虑油槽结构的摩擦片三维瞬态热传导有限元模型.借助ANSYS软件,分析了不同油槽宽度摩擦片的瞬态温度场,给出了摩擦片最高温度随时间的变化曲线和径向温度分布规律.结果表明,摩擦片最高温度出现在结合时间段中间附近,随油槽宽度增加摩擦片最高温度略有降低;由于油槽的影响,摩擦片径向温度呈阶跃分布,结合完成后摩擦片表面出现椭圆形热斑.     

Measurement of the properties of liquids and gases using a transient hot-wire technique

A transient method of making simultaneous, in situ measurements of the thermal conductivity, volumetric specific heat, and kinematic viscosity of liquids and gases is presented. The technique utilizes the temperature response record of a fine horizontal wire, functioning as a resistance thermometer, when subjected to a sudden and constant electrical heating. It is shown that a formulation of the transient mechanisms governing the transition from pure conductive to free convective heat transfer from the wire can be used to produce simultaneous determinations of fluid properties from a single wire temperature versus time record. A simple apparatus is presented, along with the results of its use in determining the properties of air.     

大型多晶硅还原炉的温度场模拟

为了提高多晶硅还原炉结构设计的安全性和指导运行过程中的冷却系统调节控制,需要全面了解在工作过程中各部件的温度分布。结合大型多晶硅还原炉研制要求,对多晶硅还原炉的辐射、导热和对流的传热过程进行传热耦合温度模拟方法研究。采用Unigraphics？建立多晶硅还原炉三维整体模型,在ANSYS CFX数值仿真平台上进行炉膛内的辐射换热、炉夹层的冷却流道冷却水系统的对流换热、炉壁各结构件的导热过程中的温度计算仿真。通过与产品设计物理模型进行比较,表明温度场数值模拟的可靠性和准确性,可以用于指导工艺参数控制。另外温度场数值模拟结果可以供还原炉设计过程中进行热结构耦合分析,以对高温高压下工作的还原炉进行安全性评估。     

Nonlinear transient heat conduction analysis of hollow thick temperature-dependent 2D-FGM cylinders with finite length using numerical method

Nonlinear transient heat conduction analysis is developed for hollow thick temperature-dependent 2D-FGM cylinders subjected to transient non-uniform axisymmetric thermal loads. It is demonstrated here that the temperature-dependency in addition to the material properties variation in the 2D- FGM would lead to highly nonlinear governing equations. To do this, the graded finite element method is employed to model the structures and a quadratic Lagrange shape function has been used to improve the accuracy of the temperature distribution for the two-dimensional heat conduction analysis. Furthermore, time variation of the temperatures and the effects of material distribution variability in two radial and axial directions and the temperature-dependency of the material properties on the temperature are discussed in detail. It is assumed that the material, geometry and volume fraction distribution are axisymmetric but not uniform along the axial direction. According to the results, the variation of the material properties in two dimensions has significant effect on temperature distribution; therefore, it gives more designing flexibility benefits to the designers to implement this kind of material for the thermal barriers purposes.     

Unsteady state work-roll temperature distribution during continuous hot slab rolling

Predicting temperature distributions in the work-rolls during the hot slab rolling process is of great importance to mill designers. This is because the temperature distribution and the dimensional accuracy of the slab being rolled are both dependent on the work-roll temperature. In addition, the life of the roll is also a function of its own temperature distribution. In this paper, the unsteady state heat transfer equations with time dependent boundary conditions are coupled with a two-dimensional finite element method to predict the work-roll temperature distribution during the continuous hot slab rolling process. To achieve an accurate temperature field, the effects of various factors including the thermal relationships of the work-roll and the metal slab, the idling work-roll revolutions, the rolling speed, the slab/roll interfacial heat transfer coefficient, and the magnitude of the thickness reduction of the slab at each deformation pass are taken into account. Comparisons between the predicted and published experimental results are used to illustrate the validity of the mathematical model.