Академический Документы
Профессиональный Документы
Культура Документы
Table of Contents
Introduction
Literature review
High temperature deformation behavior
Furnaces with loading provisions
Objectives
Proposed Design
Dimensions of the furnace
Designing the heating element
Calculations
Materials and instruments used
Methods of fabrication adopted
Results
Discussions
Conclusion
Scope of future work, Novelty
References
Introduction
Literature Review
Ilori, (1991,Nigeria) examined the detailed aspects and constraints
faced while designing an resistance furnace.
Benoit Boulet, Gino Lalli, Mark Ajersch (2003) performed an analysis
on the control of an electric furnace.
Chu, S.N.G And Li, J.C.M, Impression creep: a new test, Journal of
material science, (1977), has a detailed description of the test
parameters.
High temperature deformation test: As the name suggests, it is the
plastic deformation occurring in materials when subjected to high
temperature situation under the action of some load. There occurs
irreversible change of shape of a crystal or an aggregate of crystals
in the solid structure of the material specimen in response to external
forces.
Some of the common high temperature deformation tests would be
creep testing at constant stress, deformation analysis at constant
strain-rate , high temperature compression test.
Objectives
To make the design a compact one - so that it can be attached to any set up
that would require this furnace.
To keep the weight of the furnace and cost of production at the minimum
possible extent.
H I 2 RT
Literature Review
gravity.
The design is accepted as more accuracy can be achieved by it and there
is lesser probability of deflections caused by any kind of forces.
Dimensions of Components.
Individual components (from top
to bottom)
MATERIALS USED
1. Mild steel: (For Lid, Base plate and Cover or Casing)
Properties of mild steel are :
Reasonably high structural strength
Hard and malleable
Mild steel can be machined and shaped easily
due to its inherent flexibility
Fig 07: Mild steel
MATERIALS USED
3. Heating element: (Nichrome wire)
Properties of nichrome wire are :
Melting point is upto 1400C
High thermal conductivity(11.3 W/mK)
Higher resistivity. At room temperature
resistivity=(1-1.5 10 6 m)
MATERIALS USED
4. High-temperature insulation wool (Ceramic wool):
Properties of the ceramic wool are :
They are lightweight and have low thermal
conductivities.
Excellent resistance to thermal shock.
Outstanding electrical resistivity.
Instruments
1. Dial Gauge (with gauge stand):
Least Count : 0.01mm
2. Variac:
Range: 0-270V
L.C : 2V
3. Controller:
Components of controller:
(i) Temperature display
(ii) Ammeter
(iii) Relay
(iv) Cut-out
Fig14 : Controller
R=
5 2 7200
= 5.9
For Q= 531.38 kJ, I= 5A, t = 7200 sec , =50 %
R:
of heating element
R resistance
d2
L = : resistivity
4
d : diameter of the spring
5.9 3.14 0.0012
Length, L=
-6
4 1.3 10
= 3.56 m
For R = 5.9 , d = 1.1 mm, = 1.3 10-6 m
9. Calculating the perimeter of the nichrome spring
Formula involved =2 r
where, r :outer radius of the helix
= 2 3.14 7
Perimeter = 43.96 mm
for r = 7 mm
43.96
= 79
Although by calculations we obtained the number of turns to be used as 79, to
have an assurance of the effectiveness of the furnace, number of turns actually
used was slightly above 100.
PROCESSES OF FABRICATION
Cutting operation:
Simple cutting was done by hacksaw and
by welding. Since plates with high
thickness are difficult to cut by hacksaws,
so welding methods using high current
were brought into action.
PROCESSES OF FABRICATION
Shaping and Drilling operations:
PROCESSES OF FABRICATION
Winding the heating element and Insulation:
The length of the wire required to produce desired
heating is calculated and marked.
The
Fig20: Ceramic
wool insulation
Results
The primary objective was to design and fabricate high
temperature deformation testing apparatus and hence the
result of this project is a well fabricated fully functional, safe
and robust prototype.
Results.
Temperature levels attained by the furnace at different input
current with time:
(b)
(d)
Fig 10: Temperature vs. time plots for input current = (a) 2A ,(b) 3A,
(c) 4A, (d) combination of 2A, 3A, 4 A.
Discussions
While starting the furnace the current needs to be set at low values (about
2A).
As can be seen from all the graphs, higher is the input current, greater is
the initial slope of the plot. After a significant amount of time, the slope of
the plot decreases and the furnace tries to approach a upper fixed
temperature.
The controller was designed to take a maximum of 8A and thus keeping a
margin of safety the maximum input current was kept at 6A.
It was noted that the temperature fluctuates somewhat from the pre-set
value once the circuit gets cut out. To reduce this effect, the current was
reduced as low as possible before reaching the particular temperature.
Weights up to 20kg applied and the structure was intact.
Conclusion
The objective was to design and fabricate a high temperature
deformation furnace. After analyzing several journal papers and
practical constraints faced, a design was prepared.
The next step was to select and design the heating element.
Nichrome was selected and fabricated in the spring form for easy
attachment to the alumina tube.
Then came the need to select the materials. Mild steel was selected
for structural components and alumina was used for the refractory
components. Ceramic wool was employed to take care of insulation.
An on-off relay mechanism was then brought in for temperature
regulation and then the entire set up was fabricated using several
operations in the workshop.
When the prototype was brought into testing phase, it displayed
0
excellent performance characteristics. Maximum temperature in
Cthe
order of 750
was easily achieved and can reach significantly
beyond that.
As per loading is concerned, the set up held its integrity upon the
application of 20 kg load. It is believed to withstand even more.
References
[1]. Ilori, B.O., Design of Electric Furnace, B. Eng Thesis; Mechanical Engineering
Department; Federal University of Technology, Minna, Nigeria,1991.
[2]. Benoit Boulet, Gino Lalli, Mark Ajersch, "Modeling andControl of an Electric Furnace"
Proceedings of the American Control Conference, Denver, Colorado June 4-6,2003.
[3]. Callister, W. D., Rethwisch, D. G., Materials Science and Engineering An
Introduction,2010.
[4]. Alaneme, K.K. and Olanrewaju, S.O. (2010) Design of a Heat-Treatment Furnace.
Journal of Minerals and Materials Characterization and Engineering, 9, 581-591
[5]. Chu, S. N. G. And Li, J. C. M , Impression creep of tin single crystal, Material
Science Engineering(1979), 39,1.
[6]. T.H. Hyde, W. Sun, A. A. Becker, Analysis of the Impression creep test method using
a rectangular indenter for determining the creep properties in welds., Int. J. Mech.
Sci. Vol. 38, No. 10, (1996), pp. 1089-1102
[7].
http://nptel.ac.in/courses/105106113/_transmission%20_towers/2_material_properties
.pdf
. Downloaded on 6/10/2014
[8]. http://www.azom.com/article.aspx?ArticleID=1175 Downloaded on 6/10/2014
[9]. James C.M. Li, Impression creep and other localized tests, Materials Science and
Engineering A322 (2002) 2342
Thank you