A Heat Loss Model of Crucible with Multi-layer Material and Vacuum Lining
-
摘要: 目前运载铝液的工业坩埚,在浇铸铝合金零件前需要再次进行加热,从而导致能源浪费、成本增加及铝液改性等问题,为提高铝液热量贮存能力,设计了一种多层材料内衬真空的新型倒锥形坩埚,并进行了数值模拟试验,根据数值计算结果推导出坩埚热损失函数方程。计算结果表明:真空层厚度为29.49 cm时,坩埚热损失率为20%。为了验证坩埚热损失函数的正确性,搭建了坩埚实物模型,试验结果表明,数值模拟计算结果与温度传感器现场采集温度值误差在5%以内,说明数值模拟结果具有较高的可信度。相对于传统坩埚结构,该结构能减少坩埚热量损失达10%以上,满足坩埚无需再次加热的需求。Abstract: The industrial crucible for carrying aluminum liquid needs to be heated again before casting aluminum alloy parts. This results in energy waste, increases cost and transforms the properties of aluminum liquid. In order to improve the capability of storing the heat of aluminum liquid, a new inverted conical crucible with multi-layer material and vacuum lining is designed. The numerical simulation is carried out, and the heat loss function of the crucible is derived from the simulation results. The calculation results show that when the thickness of the vacuum layer is 29.49 cm, the heat loss rate of the crucible is 20%. In order to verify the correctness of the heat loss function of the crucible, a physical model of the crucible was built. The results show that the numerical simulation error of the field acquisition temperature of the temperature sensor is less than 5%, indicating that the numerical simulation results have high reliability. Compared with the traditional crucible, the heat loss of the current crucible decreases by more than 10%, and the crucible does not need to be reheated.
-
Key words:
- crucible /
- heat loss /
- multi-layer material /
- vacuum lining /
- numerical simulation
-
表 1 坩埚各层材料及厚度
层编号 材料 厚度/mm 1 耐热浇注料层 50 2 铸铁层 30 3 纳米微孔材料内层 20 4 真空层 L 5 纳米微孔材料外层 20 6 铸钢层 30 表 2 各层材料热通量
真空层
厚度/cm各层材料热通量q/(W·m-2) 耐热浇注料层 铸铁层 纳米微孔材料内层 纳米微孔材料外层 铸钢层 结构钢 1 2 803.39 5 586.44 1 056.96 88.23 986.35 3 380.33 10 2 845.31 5 592.29 1 075.51 45.32 706.68 2 247.59 20 2 794.09 5 318.06 1 085.80 26.56 597.29 1 940.01 30 2 742.57 5 078.45 1 090.58 16.58 532.29 1 773.28 40 2 694.05 4 866.77 1 092.66 10.71 488.38 1 662.77 50 2 696.42 4 865.31 1 090.42 7.59 441.48 1 565.62 60 2 650.53 4 676.75 1 090.49 5.47 417.11 1 604.33 表 3 坩埚内衬各层结构最大温差
坩埚内衬结构 温差/K 耐热浇注料层 429.64 铸铁层 192.58 纳米微孔隔热内层 516.33 纳米微孔隔热外层 19.30 铸钢层 11.87 表 4 坩埚各层热通量试验与仿真值对比
热通量/(W·m-2) 试验值 仿真值 qA 2 650 2 742 qB 4 600 5 078 qC 1 035 1 090 qD 10 16 qE 600 532 -
[1] 卜伟.铸铁熔铝坩埚水基涂料性能的研究[D].哈尔滨: 哈尔滨工业大学材料工程学院, 2016 http://www.wanfangdata.com.cn/details/detail.do?_type=degree&id=D01101888Bu W. Study on the properties of cast iron crucible water-based coating for molten aluminum[D]. Harbin: Harbin Institute of Technology School of Materials Engineering, 2016(in Chinese) http://www.wanfangdata.com.cn/details/detail.do?_type=degree&id=D01101888 [2] 林育炼, 刘盛秋.耐火材料与能源[M].北京:冶金工业出版社, 1993Lin Y L, Liu S Q. Refractories and energy[M]. Beijing:Metallurgical Industry Press, 1993(in Chinese) [3] 刘杰坤, 陆华忠, 李君, 等.嵌套真空板冷藏箱体保温性能的建模分析[J].西北农林科技大学学报(自然科学版), 2016, 44(8):276-234 http://d.old.wanfangdata.com.cn/Periodical/xbnydxxb201608033Liu J K, Lu H Z, Li J, et al. Thermal insulation model for refrigerated box with embedded vacuum insulation panels[J]. Journal of Northwest A&F University (Natural Science Edition), 2016, 44(8):276-234(in Chinese) http://d.old.wanfangdata.com.cn/Periodical/xbnydxxb201608033 [4] Brischetto S, Carrera E. Coupled thermo-mechanical analysis of one-layered and multilayered plates[J]. Composite Structures, 2010, 92(8):1793-1812 doi: 10.1016/j.compstruct.2010.01.020 [5] Papathanasiou T K, Markolefas S I, Filopoulos S P, et al. Heat transfer in thin multilayered plates-part I:a new approach[J]. Journal of Heat Transfer, 2011, 133(2):021302 doi: 10.1115/1.4002630 [6] Kumar S, Mahulikar S P. Selection of materials and design of multilayer lightweight passive thermal protection system[J]. Journal of Thermal Science and Engineering Applications, 2015, 8(2):021003 http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=3598ba4638f8f044ddfdd7e45705ab86 [7] Wang Q, Xie G N, Xiao M Y, et al. Sizing optimization of lightweight multilayer thermal protection structures for hypersonic aircraft[C]//Proceedings of the ASME 2012 International Mechanical Engineering Congress and Exposition. Houston, Texas, USA: ASME, 2012: 73-80 [8] 刘佳.具有纳米保温内衬的新型钢包结构的CAE研究[D].武汉: 武汉科技大学, 2015Liu J. CAE of new structure ladle with the nanometer adiabatic material[D]. Wuhan: Wuhan University of Science and Technology, 2015(in Chinese) [9] 周建安, 谢剑波, 王宝, 等.新型真空壳钢包研发[J].炼钢, 2017, 33(2):38-42 http://d.old.wanfangdata.com.cn/Periodical/lg201702007Zhou J A, Xie J B, Wang B, et al. Investigation and development of a new type ladle with vacuum wall[J]. Steelmaking, 2017, 33(2):38-42(in Chinese) http://d.old.wanfangdata.com.cn/Periodical/lg201702007 [10] Gruber D, Andreev K, Harmuth H. FEM simulation of the thermomechanical behaviour of the refractory lining of a blast furnace[J]. Journal of Materials Processing Technology, 2004, 155-156:1539-1543 doi: 10.1016/j.jmatprotec.2004.04.249 [11] 王计敏, 闫红杰, 周孑民, 等.铝熔炼炉炉衬组合的优化模拟[J].中南大学学报, 2012, 43(4):1523-1531 http://d.old.wanfangdata.com.cn/Periodical/zngydxxb201204051Wang J M, Yan H J, Zhou J M, et al. Numerical simulation and optimizing combination of aluminum melting furnace linings[J]. Journal of Central South University, 2012, 43(4):1523-1531(in Chinese) http://d.old.wanfangdata.com.cn/Periodical/zngydxxb201204051 [12] 胡亚才, 姜周曙, 沈杏云, 等.平壁导热传递函数研究[J].浙江大学学报, 1998, 32(6):761-768 http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=QK199800967319Hu Y C, Jiang Z S, Shen X Y, et al. The study of the transfer function of heat conduction in flat plate[J]. Journal of Zhejiang University, 1998, 32(6):761-768(in Chinese) http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=QK199800967319 [13] 王秉铨.工业炉设计手册[M].2版.北京:机械工业出版社, 1996Wang B S. Gongyelu sheji shouce[M]. 2nd ed. Beijing:China Machine Press, 1996(in Chinese) [14] 黄厚诚, 王秋良.热传导问题的有限元分析[M].北京:科学出版社, 2011Huang H C, Wang Q L. Heat transfer finite element analysis[M]. Beijing:Science Press, 2011(in Chinese) [15] 饶森林.多晶硅铸锭炉热场设计及计算机模拟[D].南昌: 南昌大学机电工程学院, 2014.Rao S L. Design and numerical simulation of thermal field for polysilicon ingot furnace[D]. Nanchang: Mechanical and Electronic Engineerig School, Nanchang University, 2014(in Chinese) [16] 王小路, 黄晋, 张友寿, 等.耐火保温材料现状及发展[J].耐火材料, 2016, 50(1):75-80 doi: 10.3969/j.issn.1001-1935.2016.01.020Wang X L, Huang J, Zhang Y S, et al. Current situation and development of thermal insulation refractories[J]. Naihuo Cailiao, 2016, 50(1):75-80(in Chinese) doi: 10.3969/j.issn.1001-1935.2016.01.020 [17] Ražnjeviĉ K. Handbook of thermodynamic tables[M]. 2nd ed. New York:Begell House, 1995 [18] Nieckele A O, Naccache M F, Gomes M S P. Numerical modeling of an industrial aluminum melting furnace[J]. Journal of Energy Resources Technology, 2004, 126(1):72-81 http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=9df22246d7e1a7ee4b32e82a22291793