Program predicts rod mill temperatures

Metal Pass has developed a web-based FDM program for rod mill temperature prediction.

Metal Pass has developed a web-based FDM program for rod mill temperature prediction.

The program calculates temperature profile (core, surface, mid-node, median) from rolling, air cooling to water box cooling.

Well developed process models make it easy to use and accurate in calculation.

Mill process models integrated into the program include those to suggest heat transfer coefficients for rolling, air cooling, and in particular, water box cooling, and those to calculate strain energy heating power.

Three types of production stages are handled: rolling, air cooling and water box cooling.

The user can add an unlimited number of stages according to the rod production practice.

For the rolling stage, strain energy can either be entered by user directly, or be calculated by the program.

Parameters to calculate the strain energy are also available from system calculation in addition to direct user input.

In each FDM node, the temperature rise due to the strain energy is based on the result of finite element analysis (FEA).

For heat transfer coefficient, the user can choose to enter the value directly, or let system suggest one.

In the water box cooling, a model for heat transfer coefficient, developed based on numerous site testing and lab experiments, is used.

In this heat transfer model, factors such as rod diameter, water flow pressure, rod surface temperature, turbulence contour etc are taken into account.

Heat transfer coefficient during air cooling is modelled based on heat transfer mechanisms: heat conduction, convection and radiation.

Stock travelling speed, environment temperature and contact with guide, roller etc, are considered in the model.

In addition, a databank for thermal/mechanical property data is built in for the system.

Temperature control is one of the primary tasks of the modern rolling process optimisation in balancing product quality and formability.

During steel wire rod production both the average rod temperature and the temperature difference between the rod core and the rod surface should be carefully controlled.

Finite differential method (FDM) has advantages in calculating cross-sectional temperature profile during rolling, air cooling, and controlled water box cooling process.

The program is developed with Microsoft.Net, a newest development environment from Microsoft.

An online demo for this program is available on the Metal Pass website.

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