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    Development of Computer Aided Heat Treatment

    Planning System for Quenching & Tempering(CHT-q/t)

    and Industrial Application

    of CHT-bfand CHT-cfM.S Thesis Defense presentation

    By

    Amarjit Kumar Singh

    Advisor: Prof. Yiming (Kevin) Rong

    Prof. Diran Apelian Thesis Committee

    Prof. R .D. Sisson. Jr, Thesis Committee

    Prof. M. A. Demetriou, Graduate Committee

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    Outline

    Introduction to Heat treatment process

    Industrial need of a simulation software

    System design of CHT- q/t Database design

    Enmeshment of Box shape workpiece

    Mechanical properties prediction after quenching

    Case study with CHT- q/t Industrial application of CHT- bfand CHT- cf

    Summary

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    Introduction to heat treatment

    Heat Treatment may be defined as heating and cooling operations applied tometals and alloys in solid state so as to obtain the desired properties.

    The main types of heat treatment applied in practice are

    Annealing

    Normalization

    Hardening and

    Tempering

    Some of the objectives of heat treatment are summarized as follows:

    Improvement in ductility

    Relieving internal stresses

    Refinement of grain size Increasing hardness or tensile strength

    Improvement in machinability

    Improvement in toughness

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    Industrial need of a heat treating software

    Furnaces are widely used for the heat treatment of mass production parts.So to optimize the heat treating process is of great significance.

    The present simulation softwares, unable to integrate the part load and

    furnace model with the heat treating process.

    Foundation of CHT- q/t

    CHT-bfand CHT-cfas the foundation of CHT- q/tfor several database andheating module

    QuenchPAD for the quenchant database.

    Challenges for development of CHT- q/t

    CHT-q/tneeds a complete database, most function modules are databaseoriented.

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    Definition of CHT- q/t

    CHT-q/tis a software tool to predict the temperature profile of load in

    batch as well as continuous furnace during heating, quenching and

    tempering of steel, then to predict the mechanical properties as Quenched

    & Tempered and finally to optimize the heat treatment process design.

    Part information

    Quenchantinformation

    Temperature vs timeof all parts

    Properties in load

    Fuel flow rate-time

    profile

    Heat-time profileof each part

    Heat transfercalculation

    Load pattern

    Input

    Output

    Furnace information

    Dynamic cooling result

    Phase

    transformation

    Property prediction

    Database

    Workpiece Material

    Furnace

    AtmosphereFuel

    Workpiece geo.

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    Function flow chart

    Describes the functionmodules, database and

    output of CHT- q/t

    Module 2Heating

    Module 5Tempering

    Heating below austenizing temperature

    Output 3Mechanical Properties

    after Quenching

    Output 5

    Mechanical Propertiesafter Tempering

    DB1Material & TTT profile DB

    Output 1Heat term &

    temperatures

    Module 4Phase transformation prediction

    (Austenite to pearlite / bainite / martensite)Comparing cooling curve with TTT diagram to

    determine microstructure

    Mapping of microstructure to properties

    DB4Quenchant DB

    Module 1Workpiece classification & enmeshment

    Workpiece shape classificationEnmeshment by Biot no.

    Output 2Cooling curve of eachworkpiece and inside

    the workpiece

    Output 4Heat term &temperatures

    Module 6Property prediction by empirical equations

    DB2Furnace DB

    Heat transfer for gas quenching in same furnaceused in heating

    Heat transfer for oil quenching in tank(load with fixture, single workpiece without fixture)

    Heat transfer for gas quenching in differentfurnace

    Initial condition

    Cooling

    Workpiece Furnace Load pattern Thermal schedule

    Module 3

    DB3

    Atmosphere DB

    DB6

    Tempering propertiesDB

    DB5Quenching properties

    DB

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    Database design

    CHT-q/tneeds extensive database to increase its applicability, as most of themodules strongly depend on database.

    The TTT and quenchant database are the new addition.

    Material and properties It comprises of workpiece as well as furnace materials.

    Considers non-linearity of properties

    Addition of TTT diagrams for steels

    Workpiece shape 13 basic shapes

    Furnace Batch & Continuous furnace for heating

    Dual chamber furnace, vacuum furnace, quenchant tank for cooling

    Atmosphere Fuels

    Quenchants Frequently used gas as well as liquid quenchants

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    TTT database development

    In CHT-q/tsteels are classified as

    Carbon steel

    Alloy steel

    Tool steel

    Stainless steel

    Steps for the conversion of the TTT diagrams in

    tabular format Convert in digital format

    Pick the start and finish curves at temperature duration of 20 deg

    The value range from Austenitic start to martensitic start

    Store Ms and Mfvalues as well

    Source: TTT diagrams taken from Atlas of Time-Temperature Diagrams forIrons and Steels

    http://nick-gd.chat.ru/index2.htm

    0

    200

    400

    600

    800

    1000

    1200

    1400

    1600

    1 10 100 1000 10000 100000

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    TTT Database as shown in CHT- q/t

    TTT Database as shown in CHT- q/t

    User has the option to add or edit the TTT database as well

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    Quenchant database development for gas quenchant

    Relationship between gas pressure and the heat

    transfer coefficient at 500 degree C and 15m/s

    Reference:Torsten holm, Soren

    segerberg, Gasquenching

    branches out,

    advanced materials

    and processes, 1996.

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    Quenchant database development for liquid quenchant

    H

    eattransfercoefficient,W/m2K

    0

    1000

    2000

    3000

    4000

    5000

    6000

    0 200 400 600 800

    Convection stage

    Boiling

    sage

    Vapor

    blanket

    stage

    TA-B TB-C

    Temperature,

    Boiling

    stage

    TA-BTB-C

    The quenchant database considers the variation of convective heat transfer coefficient in

    all the three stages i.e. film boiling, bubble boiling and convection stages during liquid

    quenching

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    Classification of workpiece

    3-step

    shaft

    2-step

    shaft

    coneBase

    Hollow

    cone

    Hollow

    cylinder

    2-stacked

    brick

    TorusSphereConeCylinderBox

    Shapes

    Class VClass IVClass IIIClass IIClass IClass

    Class I

    The enmeshment was one dimensional for CHT- bfand CHT- cfThe desired output of the hardness value at all the internal locations of part led

    to the development of 3-dimensional enmeshment.

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    3-Dimensional enmeshment

    Classification of workpiece by Biot number

    Case 1: Lumped heat capacity model

    Case 2: Exact model

    Lumped heat capacity modelInput Conditions:

    The dimensions of the box (D1, D2, & D3).

    The initial temperatures of the part.

    Temperature of the quenchant gas.

    Where, Ta is the ambient temperature

    Ti is the initial temperature of part

    F0 (Fourier number) is and

    Thus we can get the final temperature T, by using the above equations

    [ ]0exp FBTT

    TTi

    ai

    a=

    20

    .

    cL

    tF

    =

    pC

    k

    =

    1.iB

    1.>iB

    Conductivity and specific heat as a function of temperature

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    Bi > .1, exact solution to be used

    Input:

    Dimensions of the box (D1, D2, & D3).

    Specify the origin as shown in the figure.

    Input the values n, l ,m

    The initial temperatures of the part.

    The time step

    Ambient or quenchant temperature.n

    Dx 1=

    l

    Dy 2=

    m

    Dz 3=

    Internal nodes

    i j k1 (1 to L-1) (1 to m-1)2 (1 to L-1) (1 to m-1)

    (n-1) (1 to L-1) (1 to m-1)

    Boundary nodes

    i j k0 (1 to L-1) 0, m1 (0 to L) 0, m n-1 (0 to L) 0, mn (1 to L-1) 0, m

    i j k0, n (1 to L-1) 00, n (0 to L) 1

    0,n (0 to L) m-10, n (0 to L-1) m

    i j k0, n (1 to L-1) 00, n (0 to L) 1

    0,n (0 to L) m-10, n (0 to L-1) m

    Corner nodes: (0, 0, 0) (n, 0, 0) (0, L, 0) (n, L, 0) (0, 0, m) (n, 0, m) (0, L, m) (n, L, m)

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    Microstructure evolution and property prediction

    Properties to be determined

    Hardness

    Ultimate Tensile Strength

    Yield Strength

    Approach: Analytical approach for asquenched. Hardness value for allthe nodes to get hardness

    distribution.

    For other properties equations used,as a function of hardness. Theaverage value of hardness used todetermine other properties.

    Database approach for as tempered.

    Module 2Heating

    Module 5Tempering

    Heating below austenizing temperature

    Output 3Mechanical Properties

    after Quenching

    Output 5Mechanical Properties

    after Tempering

    DB1

    Material & TTT profile DB

    Output 1Heat term &

    temperatures

    Module 4Phase transformation prediction

    (Austenite to pearlite / bainite / martensite)Comparing cooling curve with TTT diagram to

    determine microstructure

    Mapping of microstructure to properties

    DB4Quenchant DB

    Module 1Workpiece classification & enmeshment

    Workpiece shape classificationEnmeshment by Biot no.

    Output 2Cooling curve of eachworkpiece and inside

    the workpiece

    Output 4Heat term &temperatures

    Module 6Property prediction by empirical equations

    DB2

    Furnace DB

    Heat transfer for gas quenching in same furnace

    used in heating

    Heat transfer for oil quenching in tank(load with fixture, single workpiece without fixture)

    Heat transfer for gas quenching in differentfurnace

    Initial condition

    Cooling

    Workpiece Furnace Load pattern Thermal schedule

    Module 3

    DB3Atmosphere DB

    DB6

    Tempering propertiesDB

    DB5Quenching properties

    DB

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    Hardness

    Microstructure after quenching

    ( )

    ( ) ( )[ ]TtTtww

    nfs

    fs

    /log

    1ln/1lnlog =

    The kinetics of the growth of ferrite and pearlite are described using the

    Avrami-Johnson-Mehl equation

    where,

    w : volume fraction of austenite transformed

    b,n : coefficient and exponent of the austenite transformation kinetics,

    t : timets : start timetf : finish time

    = 0.01

    = 0.99

    ( )( )Tt

    wb

    s

    s=

    1ln

    sw

    fw

    ( )nsttbw = .exp1

    ( ) ( )( )( )TMwww sBPM = .011.exp1*1

    Reference: V. C. Prantil, M. L. Callabresi and J. F. Lathrop, SimulatingDistortion and Residual Stresses in Carburized Thin Strips, vol. 125, April 2003

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    Hardness Calculation

    A continuous cooling curve is

    divided into constant temperature

    steps with appropriate times . It is

    assumed that the horizontal partsof this step function cause a

    transformation comparable to the

    transformation occurring at the

    individual temperatures in theisothermal TTT-diagram. By an

    iteration of the transformation

    steps the final microstructure is

    derived.

    Tempera

    tureT

    Time t Time log t

    step function

    real courseof cooling

    M

    B

    P

    A

    HV

    HV

    HV

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    Regression Analysis

    Hardness=f(C%, Martensite%)

    The equations of the form:

    H= ax2 +bx+c,x--- C%

    The equation at 50% Martensite

    y = -19.0476 x^2 + 64x + 20.1448

    The equation at 80% Martensitey = 7.14286 x^2 + 50.6429x + 25.6529

    Similarly, generating the HRC value for all the martensitic percentage points

    Reference:http://people.hofstra.edu/faculty/Stefan_Waner/RealWorld/newgraph/regressi

    onframes.html

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    Ultimate tensile strengthUTS=a*HB+b

    Brinell hardness is used

    Aim is to find constants a and b.

    Value of constants for stainless steel

    Validation for low alloy steel (5140) having hardness of 167 HB.

    UTS calculated by the mentioned equation comes to be 572.278 MpaAnd the UTS of a specimen having hardness 167 HB should be 573 Mpa

    Reference: Mechanical properties of Work Materials, Edmund Isakov

    Validation source:http://www.efunda.com/materials/alloys/alloy_home/steels.cfm

    U.T.S = 508 HB - 3900(156-595) HBAISI 400-seriesMartensitic

    U.T.S = 430 HB + 6530(140-190) HBAISI 400-seriesFerritic

    U.T.S = 534 HB - 16280(190-370) HBAISI 300-seriesAustenitic

    U.T.S = 457 HB + 16910(140-180) HBAISI 300-seriesAustenitic

    U.T.S = 606 HB - 31600(250-400) HBAISI Type 201Austenitic

    Ultimate tensile strengthHardness RangeDesignation and GradeClass

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    Hardness Conversion tablesConversion of HRC to HB

    HB = 17.602 HRC - 403.86661

    HB = 19.038 HRC - 489.46056

    HB = 15.962 HRC - 318.75551

    HB = 12.473 HRC - 142.65046

    HB = 10.025 HRC - 30.84541

    HB = 8.872 HRC + 16.04036HB = 8.379 HRC + 33.73531

    HB = 6.984 HRC + 76.13026

    HB = 5.329 HRC + 119.62520

    tofrom

    to Brinell Hardness (HB)

    Numbers

    (HRC)

    Equations to convert Rockwell hardness

    (HRC)

    Rockwell

    Hardness

    Conversion of HV to HB

    HB = 0.940 HV - 0.2670500

    HB = 0.909 HV + 15.1499400

    HB = 0.944 HV +1.2399300

    HB = 0.922 HV + 7.3299250

    HB = 0.954 HV - 0.7249200

    HB = 0.949 HV + 0.9199150

    HB = 0.959 HV - 0.814985

    tofrom

    into Brinell Hardness (HB)Number (HV)

    Equations to convert Vickers

    hardness (HV)

    Vickers

    Hardness

    Reference: Mechanical properties of Work Materials, Edmund Isakov

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    Calculation of Yield Strength

    The materials are classified into three categories, plain carbon, low alloy and

    alloy steel.

    For plain carbon steel kis between 0.6 to 0.65, for low alloy steel kis 0.65 to

    0.75, and alloy steel kis 0.84 to 0.86.

    The value of k has been further refined and added in the database for each

    grade of steel.

    k = Yield strength / U.T.S

    bs k =

    Reference:

    http://www.efunda.com/materials/alloys/alloy_home/steels.cfm

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    Implementation

    Case Study 1 at American Heat Treating, CT

    Material: Alloy Steel 4340Weight: 0.3 lbsFurnace: VFS Vacuum Furnace

    Load : 5 baskets arranged load

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    Case Study 1 at American Heat Treating, CT

    Quench Gas Atmosphere Nitrogen

    Quench Pressure 2 bar

    Blower HP 160

    40200Nitrogen (2bar)

    Quenching

    501950VacuumSoaking

    1201750VacuumSoaking

    1801000VacuumSoaking

    From room

    temp.

    70-1000VacuumHeating

    Time (mins)Temperature

    (F)

    Atmosphere

    Content

    Process

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    Comparison of calculated and measured results

    0

    500

    1000

    1500

    2000

    2500

    0 100 200 300 400 500

    TC1(top)

    TC2

    TC3TC4

    TC5

    TC6

    TC7

    TC8

    TC9

    TC10

    TC11

    TC12(BOT)

    CALC_S

    CALC_F

    Case Study 1 at American Heat Treating, CT

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    Case Study 2 at Bodycote, Worcester, MA

    Workpiece Stainless steelQuench Gas Atmosphere Nitrogen

    Quench Pressure 2 bar

    Blower HP 200

    Furnace Abar Vacuum Furace

    2001900VacuumSoaking

    from roomtemp.

    70-1900VacuumHeating

    200200Nitrogen (2 bar)Quenching

    Time (mins)Temperature

    (F)

    Atmosphere

    Content

    Process

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    Case Study 2 at Bodycote, Worcester, MA Measured & Calculated results

    0

    500

    1000

    1500

    2000

    2500

    0 100 200 300 400 500 600

    Time (mins)

    Temperature(F)

    Meas. slow

    Meas. fast

    Calc. furnace

    Set Point

    Calc. fast

    Calc. fast

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    Case Study 2 at Bodycote, Worcester, MA

    Dynamic cooling results

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    Summary and future work

    Discusses the function and domain of CHT- q/t

    CHT- q/tdesigned to meet industrial need, close contact with industrieskept to review their needs and implement the idea.

    The basic advantages lies in short computation time, easy to use and the

    ability to integrate the part load and furnace model with the complete heattreatment process.

    Database development (especially TTT and quenchant database)

    Development and validation of property prediction module

    Validation of the new interface as well as cooling module in industry.

    Future work More case studies required to validate the system

    Enhance database for TTT diagram and quenchant Analytical approach to find convective heat transfer coefficient

    Analytical approach to find properties after tempering

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    Industrial Applications of CHT- bf

    Case studies performed at Bodycote ThermalProcessing, Worcester

    Objective To study the effects of change in the load quantity and giving

    recommendations for the thermal schedule redesign.

    To study the effect of change in load arrangement and determination ofoptimal load pattern from the calculated temperature values.

    To determine the pre-heat required to reach the set point temperature andhence to determine cycle time.

    Scheduling of jobs in furnace after determining exact cycle time.

    To study the effect of part orientation on the quality and distortion andhence to determine best suited load orientation.

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    Pit Furnace

    Alloy, 1000lbsOthers

    Alloy, 100lbsSupports

    Graphite, 50lbsHeating

    elements

    Furnace Accessories data

    (weight and material)

    0Rate of

    cooling water

    35Weight

    1140 R.P.MSpeed

    4.5Height

    14Diameter

    2Horse power

    303Material

    [ x] Yes [ ] NoRecirculation Fan

    (one fan at top)

    [ ] Yes [ x ] NoVacuum Furnace

    NoExcess of preheated air (%)

    No preheatAir preheated temperature

    AirAtmosphere content

    120 kw or 409416.58 BTU/hrConnected heat input

    1000Minimum Operating Temperature

    2500 FMaximum Operating Temperature

    45 x 60Work space (LengthWidth Height) or

    (diameter Height)

    5 x 8External size(LengthWidth Height) or

    (diameter Height)

    ElectricHeating type(E.g. direct/indirect fired, electric)

    VerticalBody Shape

    (E.g. vertical, Horizontal)

    Pit furnace, 416Furnace name

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    Case study 1 at Pit furnace

    Workpiece Information

    2Work piece weight

    1137Work piece Material

    R. H. HandlesWork piece Name

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    Load Pattern

    362Total weight of workpiece in fixture, lbs

    181Total quantity of workpiece in fixture

    ArrangedLoad pattern, Fixture configuration

    35, 25Fixture size (diameter , height) inch

    300 lbsFixture weight

    SolidSide wall, bottom (solid/net like)RoundFixture shape (rectangular/round)

    BasketFixture type (basket/plate)

    Arrangement of load pattern

    11

    Ring

    1019Ring 5

    14Ring 920Ring 4

    16Ring 821Ring 3

    17Ring 722Ring 2

    18Ring 623Ring (Row)1

    QuantityRowQuantityRow

    Quantity in each ring

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    Comparison of result (soaking time: 305 min)

    Temperature-Time chart

    0

    200

    400

    600

    800

    10001200

    1400

    1600

    1800

    0 100 200 300 400

    Time (min)

    Temp(F) Part (slow)

    Part (fast)

    Furnace

    Conclusion: Part Temperature remains almost constant after 180 mins. The

    optimum cycle time prior to heat treating can be determined.

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    Comparison of result (Reduced soaking time:

    180 min)

    Temperature-Time chart

    0

    200

    400

    600

    800

    1000

    1200

    1400

    1600

    1800

    0 50 100 150 200

    Time (min)

    Temp(F) Part (slow)

    Part (fast)

    furnace

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    Case study 2

    Two types of part(same material)

    present in the load

    1. Qty = 300 2. Qty = 903

    Wt. = 41 Wt. = 45Thus average workpiece wt =

    0.0715

    Work piece weight

    17-4 stainless steelWork piece Material

    Hitchiner part no. 87296 & 87292Work piece Name

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    Load pattern

    (41 + 45)/2 = 43

    Total weight of workpiece in fixture,

    lbs

    (300 + 903)/2 =

    601Total quantity of workpiece in fixture

    RandomLoad pattern, Fixture configuration

    35, 25Fixture size (diameter , height) inch

    300 lbsFixture weight

    SolidSide wall, bottom (solid/net like)

    RoundFixture shape (rectangular/round)

    BasketFixture type (basket/plate)

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    Comparison of Result

    Actual result

    0

    500

    1000

    1500

    2000

    2500

    0 50 100 150 200 250

    Time (min)

    Temp

    (F) Temp (furnace)

    Temp (slow)

    Temp (fast)

    Conclusion: Great opportunity to reduce the cycle time

    All 405F

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    All case furnace

    2 G.P.MRate of cooling

    water

    200Weight

    1800 R.P.MSpeed

    14.5 inchesHeight

    10 inchesDiameter

    5Horse power

    330Material

    [x ] Yes [ ] No (one fan at top)Recirculation Fan

    900Opening area (inch2)

    [ ] Yes [ x ] NoVacuum Furnace

    15Excess of preheated air (%)

    850Air preheated temperature (F)

    Endothermic (RX) with enriching gas, dilution

    air and ammonia additions

    Atmosphere content

    1000000, 60000 Btu/hrConnected heat input

    Natural gasFuel (combustion air)

    1400Minimum Operating

    Temperature

    1800Maximum Heating

    30-48-30Work space (WidthLength

    Height) or (diameter

    Height)

    5.5 4.7 4.8 ftExternal size(LengthWidth

    Height) or (diameter Height)

    Indirect gas firedHeating type

    (E.g. direct/indirect fired,

    electric)

    HorizontalBody Shape

    (E.g. vertical, Horizontal)

    All case, 405Furnace name

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    Case study on all case furnace (with connected

    heat input 600,000 Btu/hr)

    0.2312 lbsWork piece weight

    8620Work piece Material

    Hitchiner 243860Work piece Name

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    Load Pattern

    140.4 lbs

    Total weight of workpiece in fixture,

    lbs

    607Total quantity of workpiece in fixture

    1 x 2 x 5

    Rows Columns Layers of fixtures

    in furnace

    RandomLoad pattern, Fixture configuration

    29, 23, 4

    Fixture size (Length, width, height)

    inch

    45 lbsFixture weight

    Net likeSide wall, bottom (solid/net like)

    RectangularFixture shape (rectangular/round)

    BasketFixture type (basket/plate)

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    Result

    Load takes around 65 minutes to

    reach the set point temperature,

    although the time allotted to reach

    the set point temperature is 30

    minutes.

    In all case furnace, 10 fixtures are

    used for the part load and generally

    the parts are randomly placed in thefixture, leaving no room to change

    the part load design.

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    Result by CHT-bf (same load in furnace with higher

    heat input i.e increasing the connected heat input to 1million Btu/hr) The time required by the load to reach

    set point temperature reduced from 65

    to 40 minutes, as we increased the

    connected heat input from 600,000Btu/hr to 1000000 Btu/hr, thus saving

    around 25 minutes.

    Conclusion: The cycle time can be

    reduced.

    Conclusion about All case furnace:

    Connected heat input is the most

    important parameter for the All-case

    furnaces. We can determine suitable allcase furnace for a specific load by

    CHT-bf

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    Application, Advantages and limitation of CHT- bf

    Determination of pre-heat and cycle time

    Helps in deciding appropriate furnace

    Designing optimum load and its arrangement

    Determination of required heat input of the furnace Low computation time make it highly applicable in industry

    User friendly interface and stability further increases its applicability

    Limitation

    Scheduling more than one type of parts of different geometry andmaterial, we have to take average dimension and a closely resembling

    material. This may affect the result.

    Needs improvement for random load pattern

    Part load may require some assumptions

    Only applicable for heating process

    Needs a furnace efficiency parameter

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    Industrial Application of CHT- cf

    Case studies performed at Bodycote ThermalProcessing, Waterbury, CT

    Objective

    To study the effects of change in the load quantity and givingrecommendations for the thermal schedule redesign.

    To study the effect of change in load arrangement, determination ofoptimal load pattern from the calculated temperature values.

    To study the effect of part orientation on the quality and distortion andhence to determine best suited load orientation.

    To study the effect of belt speed and gross productivity on the thermalprofile of parts and hence determine optimum belt speed and loadcapacity to maximize productivity.

    [ ] i [ ]bB d Sh

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    Mesh Belt Furnace

    0051600Air505250004

    0011600Air727000003

    0001600Air728750002

    000500Air1363000001

    Through

    metal

    area

    (in2)

    Wall

    Insulatio

    n height(in)

    Fan

    Hors

    epowe

    r (HP)

    Zone

    temperat

    ure(F)

    Atmos

    phere

    content

    Len

    gth

    (in)

    Connecte

    d heat

    input(Btu/hr

    )

    Z

    o

    ne

    90Furnace efficiency % (based on furnace age)

    [ ] Yes [x ] NoVacuum Furnace

    15Excess of preheated air (%)900Air preheated temperature (F)

    Natural gasFuel

    0Opening area of the end zone (in2)

    324Opening area of the entrance zone (in2)

    [x] internal [ ] externalBelt or conveyor return0.27Moving belt/conveyor unit weight (lbs/in2)

    54Moving belt/conveyor width (in)

    56 x 56Work space (Width Height)

    Or (diameter ) (in)

    90 x 96External size(Width Height)

    Or (diameter ) (in)

    [ ]Direct [x]indirect fired

    [ ]electric

    Heating type

    [ ]pipe [x]boxBody Shape

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    Case study 1

    0.04 lbsWeight

    1020 carbon steelMaterial

    XHD005 screwName

    0.25 inchWorkpiece width

    0.25 inchWorkpiece length

    0.25 inchHeight of layers

    0.156 inchWorkpiece height

    54 inchActual load width

    600 lbs/hrGross productivity

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    Result by CHT-cf & Measured result

    Measured result

    0

    200

    400

    600

    800

    1000

    12001400

    1600

    1800

    0 20 40 60 80

    Time (min)

    Temp(F)

    Channel 5 (Left)

    Channel 1 (Right)

    Channel 3 (center)

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    C d 2 (d i diff l d

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    Case study 2 (demonstrating different load

    patterns)

    0.02Work piece weight (lbs)1020 carbon steelWork piece Material

    14004 standard screwWork piece Name

    0.125Workpiece height

    2Workpiece width

    2Workpiece length

    0.375Height of layers (in)

    54Actual load width (in)

    600Gross productivity

    (lbs/hr)

    R d l d

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    Random load

    Arranged load

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    Arranged load

    Manual load arrangement

    Arranged load clubbing 15 parts as 1.

    Weight, part load pattern changed accordingly

    Improvement in result

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    Improvement in result

    Uniformity of thermal profile in load

    Better quality achieved (confirmed by the quality department)

    Application and advantages of CHT cf

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    Application and advantages of CHT- cf

    The affect of part load arrangement can be studied using CHT-cf, prior torunning the actual load. As shown in the case studies uniformity oftemperature can be achieved by choosing arranged load pattern.

    Orientation of parts: We can judge the part orientation, which givesuniformity in temperature

    The affect of belt speed on the thermal profile of parts can be studied,and the optimum belt speed (i.e cycle time ) can be determined.

    Furnace Planning: CHT-cfcan help us in determining the importantparameters required for the furnace, e.g connected heat input required for

    each zones, which can help in deciding the number of burners requiredfor each zones.

    Limitation of CHT cf

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    Limitation of CHT-cf

    In the Atmosphere content, only atmosphere name can be mentioned. Nooption to quantify the atmosphere content.

    While simulating the part load by CHT-cf, distortion of parts are notconsidered, while in actual industrial practice the cycle time, productionrate and load pattern arrangement are mostly considered keeping in viewthe final quality and distortion.

    Need to make the program stable and user friendly. Sometimes it givessome extra profiles in the temperature-time chart.

    Summary

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    Summary

    Several case studies validated with experimental results (using thermocouple)

    Accuracy of the temperature profiles predicted by CHT-bfand CHT-cf

    Judgment and approximation required in defining part load

    Described the methods to troubleshoot CHT-bfand CHT-cf

    Discussed in detail all the features

    i.e, database management

    Case studies and the experience

    helped in development ofCHT- q/tas well

    Motivation to work closely

    with industries

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    Thanks for your attention

    QUESTIONS ?