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3-D temperature distributions of strip in CAL were calculated by two methods.
Crown of rolls has a signicant inuence on the transverse temperature distribution of strip.
Phase transformations have a signicant inuence on the longitudinal temperature distribution of strip.
3-D temperature distributions of strip in CAL can be used to predict the residual stress and warpage of strip.
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 4 December 2012
Accepted 31 March 2013
Available online 17 April 2013
In this study, the three-dimensional (3-D) temperature distributions of strip in the whole continuous
annealing line (CAL) were evaluated by using the techniques of energy balance method (EBM) and nite
element method (FEM). The results show that both the effects of ferriteeaustenite phase transition of the
steel strip and the thermal contact resistance between the strip and taper rolls have very signicant
inuence upon the distributions of temperature. These taper rolls tend to introduce the non-uniform
distributions of the temperature and plastic deformation along both the width and thickness of the
strip which are closely related to the phenomenon of warping during punching process. Although the
computational time by EBM is very short compared to that by FEM, the results evaluated by these two
methods are well consistent.
2013 Elsevier Ltd. All rights reserved.
Keywords:
Continuous annealing line (CAL)
Finite element method (FEM)
Energy balance method (EBM)
Thermal contact resistance
1. Introduction
The continuous annealing line (CAL) is characterized by faster
delivery and higher thermal efciency than conventional batch
annealing and can provide a sound heat treatment on the strip
materials with higher quality. Sound control of the temperature
along the continuous annealing furnace is important to guarantee
the physical properties of the nal product and to save energy of
operation. In the CAL, the crowns with various proles are given to
hearth rolls for the purpose of preventing strip snaking. However,
these crowns easily introduce non-uniform distributions of temperature along the width which may result in the local plastic strain
due to both the thermal and mechanical loadings. These local
plastic strains of the strip material will then be accumulated and
nally may lead to the residual stress and warpage of the strip
242
Nomenclature
surface area, m2
specic heat at constant pressure, J/kg-K
strip thickness, m
Youngs modulus, GPa
least square error
view factor
traction, N/m2
Gebhart factors
heat transfer coefcient, W/(m2-K)
equivalent heat transfer coefcient, W/(m2-K)
strip thickness, m
side length of strip, m
number of surfaces in enclosure
Nusselt number
Prandtl number
heat ux, W/m2
heat transfer rate, W
conductive heat ux, W/m2
qC
qR
convection/radiation heat ux, W/m2
r
radial distance from the center, m
R
radiative exchange factors for application of Gebhart
method
Ra
Rayleigh number
thermal contact resistance, (m2-K)/W
Rc
Re
Reynolds number
surface, m2
SF
t
time, s
T
temperature, K
atmosphere temperature in furnace, K
TN
u
strip speed, m/s
displacement vector, m
ui
U
displacement, m
V
control volume, m3
w
strip width, m
X,Y,Z; x,y,z Cartesian coordinates
a
phase of ferrite
ath
thermal expansion coefcient, 1/K
aR
thermal diffusivity of roll, m2/s
g
phase of austenite in steel material
emissivity
strain tensor
ij
q
coordinate in circumferential direction
q0
angular width of the periphery in contact with strip
A
cp
e
E
Er
F
Fi
G
h
heq
H
LS
n
Nu
Pr
q
Q_
l
m
n
r
s
sij
sn
sy
u
d
Dt
Subscripts
ce
ceiling
cond
conduction mechanism
conv
convection mechanism
en
enclosures
oor
hp
heating plate
hp-l
to indicate heat transfer rate from heating plate to
enclosure placed on left
hp-r
to indicate heat transfer rate from heating plate to
enclosure placed on right
i,j
generic surface index
in
refers to enclosure inlet conditions
loss
losses through walls
out
refers to enclosure outlet conditions
rad
radiation mechanism
R
rolls
s
strip
s-a
to indicate heat transfer rate from strip to enclosure
located above
s-b
to indicate heat transfer rate from strip to enclosure
located below
s-l
to indicate heat transfer rate from strip to enclosure
located on left
s-r
to indicate heat transfer rate from strip to enclosure
located on right
sw
side walls
S-H
strip in horizontal position
S-V
strip in vertical position
w
walls
ws
inner surfaces of walls
Ns
thermal conditions in surroundings of furnace
Nen
thermal conditions in enclosure atmosphere of furnace
243
left side and moves alternately upward and downward. The total
numbers of major rolls in PHS, HS, SS, and CS are 1, 13, 7 and 1,
respectively. As the steel strip is moving through the taper rolls, the
thermal contact conductance between the strip and rolls should be
taken into account. Indirect radiative heating tubes are utilized in
the PHS, HS, and SS, while turbulent jets of air are installed in CS to
quench the strip. These heating tubes are situated between both
sides of the strip. Combustion of coke oven gas or propane takes
place inside these heating tubes. Since a great number of heating
tube rows in types of multiple U shape and W shape are arranged in
the PHS, HS, and SS of CAL, they can be satisfactorily considered as
heating planes in thermal model. These heating planes supply the
thermal energy to the strip, the walls and the furnace atmosphere.
The atmosphere of the furnace is made up of a mixture of nitrogen
and hydrogen (93%N2 and 7%H2). The materials used for the furnace
walls are described in Table 1, including the ceiling, the side walls
and the oor. The ceiling and the side walls are made of the superimposition of the rst ve materials, and the oor is made of the
last two materials. The detail dimensions in various furnaces are
shown as in Table 1. The input data of computational model include
the furnace dimension, the strip dimension (1204 0.503 mm), the
physical properties of the walls [1], strip velocity (3.3 m/s), strip
density (7860 kg/m3), and the temperature at entry (298 K). The
temperature of air is not uniform throughout the furnace. The atmosphere temperatures at different zones experimentally
measured by thermocouples are listed in Table 2, in which the
zones divided in each section are shown in Fig. 2. The physical
properties of the atmosphere are listed in Table 3 [2,3]. The sizes of
rolls are shown in Table 4. In addition, the view factors between
two any components of enclosure can be calculated by the formula
in the article [6].
Fig. 3 shows a representative enclosure to illustrate the energy
balance for each of the components in the enclosures, including the
heating plate, the walls, the strip and the enclosure. The associated
relations of energy balance at each following component in the
furnace can be expressed as [2]:
(1) Heating plate
Energy balance should be remained at the heating plate. In other
words, the heat supplied by the heating plate should be equal to
total heat moving out of the heating plate via the convection and
the radiation, as shown in Fig. 3, and can be written as
2. Mathematical model
2.1. EBM scheme to evaluate strip temperature
A simplied scheme of components in CAL considered in the
present study is illustrated in Fig. 2, which includes PHS, HS, SS, and
CS. In EBM scheme, the individual dimensions of PHS, HS, SS, and CS
were 17.828 3 2.3 m, 22.62 11.9 2.4 m, 22.62 6.75 2.4 m
and 25.02 3.8 3.2 m, and were divided into 7, 30, 13 and 7
enclosures, respectively. The strip is fed into the furnace from the
Q_ hp Q_ conv;hpen
Q_ rad;hpj
(1)
j ce;sw;fl;s
Table 1
Materials used for ceiling, side walls and oor [1].
Material
t, mm
t, mm
t, mm
t, mm
l, W/(m-K)
PHS (ce/sw)
30/30
50/50
35/35
37/37
3/3
HS (ce/sw)
30/30
50/50
35/35
37/37
3/3
SS (ce/sw)
96/48
162/81
114/57
120/60
8/4
CS (c/sw)
96/48
162/81
114/57
120/60
8/4
2 107T2
2 107T2
2 107T2
107T2 8
0.015T 9
Floor
Calcium silicate
Insulating re brick JM23
PHS
150
115
HS
150
115
SS
283
217
CS
283
217
2 105T 0.0239
2 105T 0.0239
2 105T 0.0132
105T 0.0014
244
Table 2
Atmosphere temperatures at different zones of CAL.
Table 4
Size of roll in CAL.
Temperature (K)
PHS
HS
SS
CS
L1
L2
D1
D2
Zone
Zone
Zone
Zone
470
469
e
e
1096
1116
1126
1136
1089
e
e
e
578
526
518
514
PHS
HS
SS
CS
500
500
500
500
210
210
575
210
340
365
300
365
750
750
750
750
749
748
749
748
0.5
1.0
0.5
1.0
1
2
3
4
shows the heat moving out of the heating plate to the ceiling, the
side wall, the oor, and the strip via the radiation.
(2) Ceiling of the furnace
Energy balance is also satised at the ceiling of the furnace. It
means the total heat absorbed by the ceiling through the convection and the radiation should equal to the heat loss to the surrounding of the furnace, as shown in Fig. 3.
Q_ loss;ce Q_ conv;ceen
Q_ rad;cej
(2)
j hp;sw;fl;s
where Q_ loss;ce denotes the heat loss from the ceiling to the surrounding of the furnace, Q_ conv;ceen represents the heat absorbed
by the ceiling from the environment via the convection, while
P
shows the heat absorbed by the ceiling from the
Q_
j hp;sw;fl;s
rad;cej
heating plate, the side wall, the oor, and the strip via the radiation.
(3) Side walls of the furnace
Energy balance is also satised at the side wall of the furnace. It
means the total heat absorbed by the side wall through convection
and radiation should equal to the heat loss to the surrounding of the
furnace, as shown in Fig. 3.
Q_ loss;sw Q_ conv;swen
Q_ rad;swj
(3)
j hp;ce;fl;s
j hp;ce;sw;s
rad;flj
heating plate, the ceiling, the side wall, and the strip via radiation.
(5) Vertical strip
The total heat absorbed by the vertical strip should equal to the
heat transferred to the left and right sides of the strip through the
convection and the radiation, as shown in Fig. 3. This net absorbed
heat leads to the increase of the strip temperature, as shown in Eq. (5).
(5)
where Q_ conv;sl and Q_ conv;sr denote the heat transferred to the left
and right sides of the strip through convection, respectively;
Q_ rad;sl and Q_ rad;sr denote the heat transferred to the left and right
represents
sides of the strip through radiation, respectively; Q_
SV
the heat absorbed by the vertical strip, rs, e, w, u and cp,S-V denote
the density, the thickness, the width, the speed and the specic
heat of the vertical strip, respectively; TS-V,out and TS-V,in are the
temperature of the vertical strip at the outlet and the inlet,
respectively.
(6) Horizontal strip
where Q_ loss;sw denotes the heat loss from the side wall to the surrounding of the furnace, Q_ conv;swen represents the heat absorbed
by the side wall from the environment via the convection, while
P
denotes the heat absorbed by the side wall from
Q_
j hp;ce;fl;s
where Q_ loss;fl denotes the heat loss from the oor to the surrounding of the furnace, Q_ conv;flen represents the heat absorbed by
the oor from the environment via convection, while
P
shows the heat absorbed by the oor from the
Q_
rad;swj
the heating plate, the ceiling, the oor, and the strip via the
radiation.
Q_ loss;fl Q_ conv;flen
Q_ rad;flj
(4)
j hp;ce;sw;s
Table 3
Properties of atmosphere [2,3].
Property
Function
Range
r, kg/m
325.38/T
1.096 104T2 5.499 102T 1054.84
6.358 105T 1.299 102
2.966 108T 1.011 105
400
400
400
400
cp, J/kg K
l, W/m K
m, Pa s
<
<
<
<
T(K)
T(K)
T(K)
T(K)
<
<
<
<
1000
1000
1000
1000
Q_ conv;jen 0
(7)
sij dij dV
V
Fi dui dS 0
P
j hp;ce;sw;fl;s
tween the surrounding and the heating plate, the ceiling, the side
wall, the oor, and the strip via the convection.
Consequently, totally seven unknown parameters in each
enclosure, including six unknown temperatures for the heating
plate, the ceiling, the side wall, the oor, and the strip in the horizontal and the vertical positions, as well as one unknown heating
power for the heating plate, can be completely determined by
solving the equations from (1) to (7).
The radiative heat transfer rates, which are calculated using the
technique of surface to surface approach, can be expressed by Eq. (8).
n
P
Ri;j Ti4 Tj4
Q_ rad;i
j1
Ri;j Ai si di;j Gi;j
Gi;j
F
i;j j
(8)
di;j 1 j Fi;j
Q_ conv;i Ai hi Ti TNen
(9)
(10)
SF
j hp;ce;sw;fl;s
where
245
246
shown in Fig. 4(a). The side length of strip, LS, as shown in Fig. 4(b),
is assumed as p times the diameter of roll for taking the heat
transfer program of nite element model into account [3]. Contact
elements are prescribed between the strip and the roll to ensure a
suitable contact condition between them. The contact stress of strip
passing through each roll can be determined by using the temperature of strip obtained by FEM. The roll is assumed to be rigid
and xed at its center, i.e., Ux UY UZ 0 at X Y Z 0.
Moreover, the displacement of strip at the central line along the Zdirection, UZ, should be also equal to zero. The boundary conditions
and constraints are shown in Fig. 4(b). Taking a rigid displacement
as load is more reasonable than a uniform tension in the actual
process [10]. A small displacement is applied at both ends of strip to
create the suitable tension (5000 10% N) performed actually by
the factory. The contact pressures between the strip and the roll are
evaluated by the nite element method and then converted to the
thermal contact resistances by using the following relation [11]
.
m2 K W
Rc sn 0:33 1:175e0:521sn 103
(11)
v2 TR 1 vTR 1 v2 TR
1 vTR
2
aR vt
r vr
r vq2
vr 2
TR x; y; z; t TN ;
t 0
(13)
ut q q0 ut
(14)
lR
vTR
T T
R
;
Rc sn
vr
lR
vTR
heq TR TN ;
vr
q0 ut q 2p ut
(15)
where aR (kR/rRcp-R) is the thermal diffusivity of roll; kR, rR, and cpdenote the thermal conductivity, density, and specic heat capacity of roll, respectively; u is the angular speed of roll; while q0
denotes the angular width of the periphery in contact with strip.
The temperature-dependent mechanical properties of the steel
strip including Poissons ratio, n(0.3), thermal expansion coefcient, ath, Youngs modulus, E, yield strength, sy [13] and specic
heat capacity [14], were shown in Fig. 5. The effect of latent heat
(76 kJ/kg) created during ferriteeaustenite phase transition can be
considered by using the modied specic heat capacity curve
adopted by Brown et al. [15] and Frewin et al. [16] in ABAQUS and
ANSYS, respectively.
The computational procedure of energy balance model was
divided into two steps. First, the temperatures of heating plane,
ceiling, side walls, oor, vertical and horizontal strips were determined in each enclosure by solving the energy balance equations
iteratively. Secondly, the strip was divided into several imaginary
narrow strips along the width direction in each enclosure. Different
view factor was specied individually in each imaginary narrow
strip. The temperatures of strip in various imaginary narrow strips
were evaluated by the temperatures of heating plane and walls
obtained previously and thermal contact resistances distributed
along the width. A 2-D temperature distribution for the strip along
the length and width was thus obtained. The owchart, as shown in
Fig. 6, represents the computational algorithm to calculate the
temperature of heating plane, walls and strip by the energy balance
equations and nite element models.
(12)
Fig. 5. Physical properties of strip [13,14].
247
v
vT
v
vT
v
vT
vT
lT
lT
lT
rTcp T
vx
vx
vy
vy
vz
vz
vt
(16)
248
4
qR s TN
T 4 h TN T heq T TN T
where
2
T 2 TN T h
heq s TN
(17a)
(17b)
qC TR T=Rc sn
(18)
where TR is the surface temperature of roll; T denotes the temperature of strip in contact to the roll; Rc is the thermal contact
resistance, that is a function of contact pressure sn.
Detailed solution procedures and algorithm of FEM scheme
were shown in Fig. 7. All the required input data, including the size
and physical properties of strip and roll, as well as the parameters
of CAL, should be provided as input data rst. It is obvious that a
numerically iterative solution procedure should be performed to
the mechanical and energy models of strip and roll. The contact
pressure and thermal contact resistance with an assumed initial
strip temperature and surface temperature of roll, generally estimated by EBM, were evaluated rst by mechanical model. A revised
temperature distribution of strip after completely passing over the
roll, that takes account of the inuence of thermal contact resistance and surface temperature of roll, was then calculated by the
energy model of strip. After that, the revised contact pressure and
the thermal contact resistance were evaluated again by mechanical
model. These solution procedures were iteratively proceeded until
a satised convergence in numerical solutions was obtained.
3. Results and discussions
The distributions of contact pressure and thermal contact
resistance in width as the strip is passing the No. 1 roll in HS were
shown in Fig. 8. It can be found that a uniform contact pressure was
induced at the central portion of the strip along the width direction,
while an extremely high peak of contact pressure was induced near
the edge of the crown. The value of contact pressure reduces to zero
near the two edges of the strip, where a signicant gap appears
between strip and roll. In other words, the situation of thermal
contact resistance disappears in these regions, where both the effects of thermal radiation and convection instead of thermal
Fig. 8. Contact pressure and thermal contact resistance of strip along the width at No.
1 roll of HS.
249
air was equal to 350 K) at central part and two sides were equal to
27 and 32 W/(m2-K), respectively. Higher equivalent heat convective coefcient in PHS was due to the higher temperature difference
between strip and furnace atmosphere. The temperature history of
strip in each section of CAL was shown in Fig. 10, where the strip
lengths in PHS, HS, SS and CS are 0e42.5, 42.5e337.2, 337.2e505.8
and 508e554.7 m, respectively. The outlet temperatures in various
sections were 401, 1058, 1080 and 923 K, respectively. A temperature gradient is produced suddenly when the strip is in contact
with each roll, since the effect of heat conductance is much higher
than heat convection and radiation. Moreover, it was found by
energy model of strip in FEM scheme that the strip temperature
always keeps uniform distribution in thickness in the whole CAL
even under such a high moving speed. In other words, only 2-D
temperature distributions of strip, i.e., along the wide and longitudinal directions, are required to be displayed and discussed.
When strip is moving in HS, the temperature of strip gradually
rises higher than 727 C and then the aeg phase transformations
occurs. On the other hand, as the temperature is decreased lower
than 727 C in CS, the reverse phase transformation from g to a
takes place. The effect of phase transformation on strip temperature is very signicant. As shown in Fig. 11, a maximum discrepancy
of 19.5 C of the strip temperature is produced in HS in case this
250
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