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NGHIEN CUfU-TRAODd PHONG VA T H V C NGHIEM T R U O N G D I £ N T VA THONG LUONG NHIET P H A N B T R £ N T A M T H E P TRONG GIA NHIET CAM U>^G : M U L A T I N S A N D E X P E R I M E N T S O F ELECTROMAGNETIC FIELD AND HEAT FLUX DISTRIBUTION ON THE STEEL PLATE IN INDUCTION HEATING NCS Tran Thi Thiiy Nga', TS Nguyen Trfldng Thinh^ PGS, TS Tran Thu Hi^ 'Trfldng Cao dang Ky thuat Cao Ihang ^TrUdng Dai hpe SU pham Ky thuat Tlianh ph6 Hd Chi Minh ITAT Detao hinh bien dang cua thep tam bdng nguon nhiet, phUdng phdp gia nhiet cdm dngdUdcsii I de thay the cho nguon nhiet Oxy-axetylen, von khong cd nhieu Uu diem viec tao hinh bien J thep tdm vd tau Gia nhiet cdm dng Id phUdng phdp dUa tren hien tUdng cdm dng dien tii, cho I dien tdn so cao chay cuon ddy, ddng dien ndy se sinh xung quanh nd mot tii trUdng hien theo thdi gian, cd tdn so ciing vdi tdn so ci^a ddng dien cudn ddy Khi ta dat ben dUdi eudn ddy, ^ vung dnh hUdng ciia tii trUdng mot tdm thep, thi trUdng dien td ndy se tao nen mgt ddng dien khep ren be mat tdm thep vd nung ndng tdm thep theo hieu dng Joule-lenz Tren cd sdphdn tich FEM, mdt I gidi phdp cho phdn tich bao gom cuon ddy dang dia vdi mgt niia vdng ddy doi xiing true dUde ldm ; vat lieu dong, tdm thep vdi vdt lieu AH-32 vd vung khdng cho phdn tich Khi tdn so dong dien ig doi, mat trUdng dien tii vd thdng lUdng nhiet phdn ho tde thdi tren tdm thep thay doi edc so gia nhiet thay doi nhU: be ddy tdm thep, khodng edeh tii vdng ddy den be mat tdm thep vd eUdng dng dien cudn ddy Sd thay doi ndy tao nen mgt vung dnh hUdng nhiet tdc thdi, tUdng dng md Udc sd dung nhu mot nguon nhiet ddu vdo trongphdn tieh ddng nhiet vd bien dang cua tdm thep ', phUdngphdp gia nhiet cdm dng TRACT To control the deformation ofplate in the steel forming process with heating, the electro-magnetic uction process has been used as the substitute of the flame heating process, which did not have many vantages in deforming the steel hull plates Induction heating, a method based on the phenomenon of ztromagnetic induction, when the high-frequency current flows through an inductor that is located zr the conductor of a steel plate This current generates a magnetic field around it varies over time, with quency the same the frequency of electric current in the inductor This electromagnetic field generate on teel plate surface an eddy current and steel plate heated by Joule-Lenz effect On the basis of FEM analy an analytical solution domain consists of a disk coil with a hafl symmetrical axis are made of copper, el plate with the material properties of the AH32 steel and air With frequency is constant, electric field d density of heat flux distribution on steel plate are change when heating parameters changes, such as ckness of steel plate, distance from the coil to steel plate surface and current in the coil This changes ate an instantaneous heat affected zone, respectively, which it is used as source of the heat input for heat w and thermal-mechanical deformation of steel plate in induction heating method Keywords: Finite element method Induction heating, Numerical analysis Electro-magnetic iniction, Heatfiux analysis, HAZ TAP rHTX^rtK-HT VIETNAM *t* Sd (Thing nam 2012) ^ NGHIEN CUfU - TRAO D O I l.GICflTHlfiU Vi^c tao bien dang ta'in thep vd tiu trUdc lap gh^p vio eac phan cua than tiu li mpt khau quan trpng nginh ddng tiu, tao nen chat Iflpng eua mdt chiec tiu vi ning cao nang canh tranh tren thi trfldng Qui trinh lao hinh bien dang thep tam vd tiu hi^n chu yeu sU dyng cic phUPng phip truyin thdng, vdn khdng linh hoat va kim hi|u qui kinh tl Die biet li phUdng phap tao hinh bien dgng vd tiu bing ngudn nhi?t sfl dung diu ddt Oxy-axetylen [1], chat lupng tao hinh bl mat eung nhfl biln dang cua tim thep phy thupc rat nhieu vio tay nghe ngUdi thp vi khd kiem soat ngudn nhi?t dau vio sudt qui trinh gia nhiet, dieu niy lim giim hilu qua eua phflpng phap Gia nhiet earn flng li phUdng phap dUde sfl dung de thay the cho ngudn nhiet Oxyaxetylen, vdn khdng cd nhieu Uu diem vile tao hinh bien dang tam thep Khi gia nhiet cim flng dupe ap dung eung vdi vile tich hpp robot cho vile tfl ddng, qui trinh udn biln dang tam thep se trd nin de dang dieu khien va kinh te hdn cie phfldng phip cu Die biet, doi vdi cic tam thip vd tau ed bien dang phfle tap, phUdng phip gia nhiit cam flng the hiln rd kha nang toi flu Cic de tii nghien cflu ve phfldng phap gia nhiet cim Ung bien dang tam thep da dupe cdng bd, phan bd nhiet hai chieu 12.3] sudt qui trinh gia nhiet camflngvdi tan sd gia nhiet cao li nhflng chu de chinh hau het cic nghien cflu vi trang thii bien dgng ba chieu cua tam thep dflpe md hinh hda bdi phan tich Tuy nhien, cae nghiln cflu da dflpc cdng bd, chfla the hi^n rd mdi quan he gifla kich thfldc viing inh hfldng nhiet cua tam thep vdi cic thdng sd lien quan sudt qui trinh qua trinh gia nhiet cam flng mi dilu nd tao nen bien dang khic cua tam thep Trong nghien cflu nay, mdt thdng Iflpng nhiet tfle thdi phan bd trin tam thep mi nd dflpc xem la mdt ngudn nhi^t dau vao phan tich ddng nhiet va bien dang tam thep se dflpc phan tich trin cp sd FEM [4] Trfldng di?n tfl vi thdng TAP CHf CO KHf V I £ T NAM lupng nhi?t phan bd tflc thdi tren tam thep dUi? phin tieh vdi cic tham sd gia nhi^t thay doi, t^ nen vung inh hfldng nhi?t khic trin cdsi phin mem COMSOL [5] Mpt loat cac thilt nghiem sau dd se kiem chflng ket qua dat dii^Jc phan tich PHAN TfCH TRUOiNG DlfeN TlT CHO T H O N G Ll/ONG N H I £ T Khi cho ddng di|n xoay chieu, cd tan so cao chay qua mpt cupn diy dflpe dit tren mgt tim thep, nhu hinh 1, mdt chum tfl thdng xuy^n qua bl mat cua tim thep ma nd ddng true m cudn diy Vi viy, ddng dien xoay dflpe sinh tai bl mat cua tam th^p Ddng di?n camflngsinh nhi?t di|n trd trin tam thep theo hieuflngJoule vi dieu niy cd the dung de udn tam thep ruinii! iticn Us thiw tli'i Wt;^ Jicn \ i u \ chicu Hinh } Mo hinh tdng qudt cua gia nhiet cdm Ung Phfldng trinh can bing cho ddng dien xoiy phan bd qua trinh gia nhiet cam ling cd the dupc suy tfl h? phflpng trinh Maxwell vung tan sd cho phep [6], -V'A-t-j(oaA = J^ (11 diy: gpi la toan tU Laplace, la vecto di?n the tfl , mat dp ddng di^n ciia ngu6n cupn day, la dp tfl tham, li van tdc gdc \^ la ^^ dan di^n Khi veetd di^n tieh cua phUdng trinh (1) dflpc phan tich ddng dien xoay va thong lupng nhiet phan bd tren tam thep cd the diif^ tinh toan Khi phfldng trinh (1), dflpe giai bang phflpng phap phin tfl hflu han, nd dUdc viet nhil S6 (Thing nam 20I2J NGHIEN Cflu-TRAO 061 •[K][AMJ] (2) , i rik i Mill); cua L'uyii day '^ +jaic7|[A']' [N]da (3) [j]=ljMdn (4) Vfli vecto dien tich diJoc riit la tiJ phiiang ' trinh (2), nhiet dien trd co the duoc tinh I' , ' (5) - ' il (a) Hrnh Mo hinh tong qudt cua cudn day vh tdm thip mo phdng trudng dien td j ^j Thdng lupng nhiet trung binh mien tan sd cd the dUpc tinh q = -fqdl^~( 'AX+a> ^A^A\) Mivii 1116 pliniit! \ Tam ihcp & day J^=ai-dA/di) la mat dO CLia dong ;d.enxo., 1.5 mm j ^ O O P ' (6) ' ® doi xvtng true 2,3vii4 O diy A' l i Uln hpp phfle cua A cdch dien vdt moi trUdng ngodi Hinh LUdiphdn tdvd dieu kien hien trongphdn tich Hinh 2, the hien md hinh dupe sfl dung TRU'CfNG DIEN T C VA THONG LUONG NHIET P H A N B T0C THOil TRONG GIA cho phin tich Cudn day bang dong, dflpc thiet ke dang dia va doi xflng true nin dupe md hinh hda I NHIET CAM LTNG vi md phdng mdt nfla dfldi dang 2D gdm vdng Ddng dien cd tan sd cao chay eudn day, dfldng kinh mdi vdng diy la mm, ban kinh diy, gay nin tfl trfldng xung quanh nd, neu dit cua cudn day li 30 mm, khoing each gifla hai vdng tfl trfldng mdt vit mdt tam thep thi tfl diy bang 1.5 mm Tam thep md phdng bang trudng se gay nin mdt ddng dien khep kin vat lieu thep AH_32 Be diy tam thep (d) thay ddi: tren tim thep vi dot ndng tam thep theo hilu Ung 10 mm, 15 mm, 20 mm, 25 mm vi 30 mm Khoang Joule Hinh dang va kich thUde vung inh hfldng cich tfl vdng day den be mat tam thep md cua tfl trfldng tren be m^t tam thep phu thude vao phdng thay ddi tfl 1.5 -;• mm Dp din dien cua hinh dang cudn diy, efldng dp ddng dien ngudn thep AH_32:6.02e4 [S/m] Dp dan dien cua vat lieu cupn day, vat lieu lam cudn diy, khoang cudn day: 7.40e7 [S/m] Tan sd ddng dien khdng each tfl vdng day den be mat tam thep, tinh chat ddi, f = 45 KHZ vi ddng dien thay ddi tU 500 A -^ cua vat lieu tam thep vi be diy tam thep Cfldng 1000 A, cho mdi trfldng hpp md phdng Mien md dp trfldng dien tfl dflpc phan tich tfl phflpng trinh phdng dflpc chia Ifldi kieu tam giac vdi 7072 phan ^ tfl vi dieu kiln bien cho giii phap nhfl hinh (1) va md phdng vdi phan mem COMSOL 3.4 TAP CHf CO KHf V I E T NAM • Sd (Thing nam 2012) NGHIEN CIJfU-TRAOD6l Thdng Iflpng nhi?t tflc thdi dflpc suy tfl phi lich trUdng di?n tfl phin bd tren tam thep thei hi?u flng Joule-Lenz, Iflu hinh va be r^nj De thUc nghiem phin tich trfldng di^n tfl vung dnh hfldng nhi?t tflc thdi trin tam thq vi thdng Iflpng nhi^t phan bd tflc thdi I ren lam dflpc phin tieh, hinh thep gia nhi^t cim flng, de tii sfl dyng thep 'ti^A^^^M^^ tam AH32 cho phan tieh, tam thep dflpc dit ben dfldi cupn day Ddng di?n eh?iy cupn diy, sinh tU trUdng xung quanh nd vi tao mpt dong dien khep kin trin bl mat tim thip vi nung ndng tim thep theo hi|u flng Joule-Lenz THUC N G H I £ M T H O N G L U ^ N G N H I £ T T C C THCJI P H A N B O T R £ N TAM T H £ P Hmh (' Mill dd tiuongdicn lu ^iiih w plumb trai U'lin Ihcp Hinh Md hinh mdy gia nhiet cdm dng Hinh the hiln dau gia nhiet dflpc sfl dung thflc nghiem Tan sd ddng dien ngudn 45 KHz, ddng dien cudn day thay ddi tfl 500 A den 800A, tam cd be diy thay ddi tfl 12 mm den 22 mm vi khoang cich tfl vdng diy den be mat tam thep li mm Ket qui phan tich dflpc tai Hinh Tdng mat ddng dien phdn bd tren tdm thep [A/m'l mat cat ngang cua tam thep, mat phang vudng gde vdi hfldng di ehuyen cua dau tfl, hinh bl = — jJ.l'*20°C >• - Hinh Bien dang vung dnh hUdng nhiet tdc thdi tronggia nhi^t cdm dng '" ' KET QUA PHAN TfCH VA THlTC N G H I £ M Trfldng dien tfl sinh xung quanh cupn diy va phin bd trin be mat tam thep, tai vung anh hfldng cua tU trfldng, hinh Tdng mat dp ddng dien sinh va phan bd tren tam thep nhfl hinh TAP CHf CO KHf VIET NAM • ~ T ' ""^ Hinh LUu tinh nhiit ciia viing dnh hUdng tdc thdi tren tdm thip Sd (Thing nam 2012)_ NGHIEN Cflu - TRAO D | Dieu niy li do, khoing each tfl vdng day den be mat tam thep li nhd nhat (1.5 mm) thi flng vdi ddng dien cd gia tri efldng dp tflpng flng, tU trfldng CLia ddng dien sinh xung quanh cudn diy vi thim siu hdn tren be mat tam thep so vdi lam thep de cich xa vong day hdn theo hilu Ung be mat, nin be rpng vung inh hfldng nhiet tflc thdi sinh tren tam thep cung ed gia tri khae nhau, tflpng flng b^- BS rdng viing dnh hitdng nhiit /i|, Chilu sdu vdng dnh hUdng nhi(t Hinh Kich thUdc vitng dnh hUdng nhiet tdc tiidi tronggia nhiet cdm dug Kich thfldc vung i n h hfldng nhiet d trang thai phin tich tUc thdi phu thupc vio b l diy tam thip, khoang cich tfl vdng day den b l mat tam thep vi efldng dp ddng dien ngudn eung ci'p, tan sd gia nhiet khdng ddi, f = 45 KHz Khi khoing cich tfl vdng diy den be mat tam thip thay doi, flng vdi cae gia tri ddng dien tfldng Ung thi cung nhU be rdng vflng inh hfldng nhiet, chieu siu vung i n h hfldng nhiet eung se thay ddi tfldng flng Hinh 11 the hien mdi quan he gifla chieu siu vung anh hfldng nhiet vdi khoing eich tfl vong day den bl mat tam thep eUdng dp ddng dien la khdng ddi cua tam day 10 mm \ Htnh 11 Mil quan he giUa chieu sdu HAZ vdi khodng cdch, cUdng ddng diin khdng doi Hinh 10 Mdi quan he giUa he rdng HAZ vdi khodng cdch, ddng dien khong doi Hinh 10, the hiln mdi quan he gifla be rdng vung anh hfldng nhiet tUc thdi trin tam thep vdi khoing each tfl vdng day din be mat tam thep eUdng dp ddng dien thay ddi eua tam thep day 10 mm Ta thay, khoang each tU vdng day den be mat tam thip l i nhd nhat (1.5 mm) thi be rpng vung anh hUdng nhiet tflc thdi trin tam thep la Idn nhat flng vdi cic gii tri cUdng dp ddng dien tuong flng va ngUdc lai, khoang each tfl vdng day den be mat tam thep Idn m m thi be rdng vung anh hfldng nhiet tfle thdi tren tam thep la 'nhd nhat flng vdi cic gia tri ddng dien tflPng flng .-.^ ^^ Ciirvni Deatitv i Hinh 12 Moi quan hi gida be rong HAZ vdi cUdng ddng diin, khodng cdch khong ddi '" C KHf V I £ T NAM V Sd (Thing nam 2012) NGHIEN c f l u - TRAO D O I be mil cae thim thep cd kich thfldc khic nhaul khdng ddi Vdi cic tam thep cd eung tinh chit,i^ li?u dupc xem li ddng nhat thi bl rpng va chlft sau cua vung i n h hUdng tfl trfldng tren tamth^ li nhfl nin vung i n h hfldng nhi?t tflc thifi sinh bdi hi^u flng Joule-Lenz tren cac timth^ li nhfl ,.^ Tfl dd thi cic hinh 10 den hinh 13, ta thiy be rpng v i chilu siu vung i n h hfldng nhiet tflc thdi se thay ddi khoang cich tfl v6ngday den b l mil tim thep thay ddi, cfldng dp ding Hinh i3 Moi quan he gida chi^u sdu HAZ vdi cUdng di|n cupn diy thay ddi v i bl diy tam dd ddng dien, khodng cdch khdng ddi thep thay ddi Die biet hinh 10 vi hinh 11,1a thay: Khi khoing each tfl cupn diy den be mat Ta thiy, khoang cich tfl vdng diy den tain thep Idn hdn hoac bing 3.5 mm thi viinganli bl mat tam thep (> 3.5 mm) thi chieu siu vung hfldng nhi|t tflc thdi tren tam thep khdng dang i n h hfldng nhiet tUe thdi trin tim thep li nhd ke, thim chi bang khdng \'i viy can chii y din nhit Dieu niy li do, khoing each tfl vdng diy khoing cich tfl vdng day den be mat ehi tiet troi^ den be mat tam thep li nhd nhat (1.5 mm) thi flng tat ca cic flng dung gia nhiet cam flng Khoang vdi ddng dien cd gii tri cfldng dp tflpng Ung, tU cich tdi Uu tfl 1.5 mm den mm trudng eua ddng dien sinh xung quanh cupn I diy va tham siu hPn tren be mat tam thep so vdi tam thep de each xa vdng day hpn theo hilu flng be mat, nin be rdng vflng inh hfldng nhiet tflc thdi sinh trin tim thep cung cd gii tri khic tfldng Ung ••I Khi khoing cich tfl vdng diy den be mat tam thep li khdng doi va be diy tam thep thay ddi Kich thude HAZ tUc thdi trin tam thep thay ddi khdng dang ke Hinh 12 v i hinh 13, the hi|n mdi quan he gifla be rdng v i chieu siu vung anh hudng nhiet tflc thdi tren tam thep cua cic t i m diy 10 -^ 30 mm, khoang cich tfl vdng diy den be mat tam thep li mm tfldng flng Ta thay, khoang each tU vdng day den be mat tam thep li khdng ddi nhflng be diy tam thep li thay ddi thi kich thfldc HAZ tflc thdi tren tam thep thay ddi khdng ding ke Dieu niy li do, khoing each tfl vdng day den be mat tam thep la khdng ddi, cfldng dp tU trUdng xung quanh cupn day sinh bdi ddng dien ed gia tri tUPng flng l i khdng doi thi vung anh hfldng cua tfl trfldng trin TAP CHf CO KHf V I £ T NAM • Hinh 14 HAZ tdc thdi tronggia nhiet cdmj (a) trongphdn tich; (b) thUc nghiim^ Hinh 14, md t i vung anh hfldng nhietliJc thdi trin tam thep dflpc suy tfl phan tich^'a thflc nghi?m khoing cich tfl vdng day d&i« mat tam thip bing mm, tan sd ddng di^n 45 KHz v i ddng di^n cudn day 800A cuatSm thep day 16 mm Sd (Thing nam 2012) NGHIEN Cflu - TRAO Ddi Ket qua gifla phan tich va thflc nghiem the hi^n tdt kich thUdc vung i n h hfldng nhiet tUc thdi j h i n bd tren tam thep Sai sd 4.03% gifla b l rpng HAZ tUc thdi phin tich va thUc nghiem va 15.3% cho chieu sau HAZ tUc thdi phin tieh vi thflc nghiem Dilu niy la sfl khdng ddng diu tua vit li^u cua eudn day cung nhfl vat lieu tam thep S KET LUAN Gia nhiet c i m flng dfla tren hien tflpng cim Ung di^n tU Khi cho mdt ddng dien cd tan sd cao :hay eudn diy, ddng dien niy se sinh xung quanh nd mdt tfl trfldng bien thiln theo thdi gian, :d tan sd cung vdi tan sd cua ddng diln ngudn Cfldng dp eua tU trfldng phu thudc vao vit lieu lim zudn day va mat dp ddng dien cudn day Vdi tinh chat tam thip dflpc xic dinh, khoing each tfl vdng day din be mat tam thep thay ddi, b l diy tam thep thay ddi v i cfldng dp ddng di^n cupn day thay ddi thi trUdng dien tU phin bd tren tam thep eung thay ddi tUdng flng, m i dilu niy tao nen vung anh hfldng nhiet tUe thdi khic tren tam thep m i nd dupe dung nhU mpt ngudn nhiet dau "vio phan tich bien dang tam thep gia nhi|t cam flng • iNgiy nhan bii: 26/5/2012 Ngiy phan biln: 02/6/2012 -Ngfldi phan bien: PGS TS Nguyen Nggc Phfldng TS Trfldng Nguyin Vu Tai lilu tham khao: [1] K-Y Bae, Y-S Yang, C M Hyun, and S-H Cho, Simplified mathematical formulas for the prediction of deformations in the plate bending process using an oxy-propane gas flame, JEM1264 _ IMechE 2008 [2] J Nerg, Numerical solution of 2D and 3D induction heating problems with non-linear material properties taken into account, IEEE Transactions of Magnetics 36 (5) (2000) 3119-3121 [3] V Cingoski, A Namera, K Kaneda, H Yamashita, Analysis of magneto-thermal coupled problem involving jnoving eddy-current conductions, IEEE Transactions of Magnetics 32 (3) (1996) 1042-1045 .[4] E Bay, V Labbe, Y Favennec, J.L Chenot, A numerical model for induction heating processes coupling electromagnetism and thermomechanics, Int J Numer Meth, Eng 58 (2003) 839-867 15] Matej Kranjc, Anze Zupanic *, Damijan Miklavcic, Tomaz Jarm, Numerical analysis and thermographic investigation of induction heating International Journal of Heat and Mass Transfer 53 (2010) 3585-3591 [6] K Sadeghipour, J.A Dopkin, K Li, A computer aided finite element experimental analysis of induction heating process of steel Computers in Industry 28 (1996) 195-205 00 KHI V I £ T NAM V Sd (Thing nam 2012) ... sinh bdi ddng dien ed gia tri tUPng flng l i khdng doi thi vung anh hfldng cua tfl trfldng trin TAP CHf CO KHf V I £ T NAM • Hinh 14 HAZ tdc thdi tronggia nhiet cdmj (a) trongphdn tich; (b) thUc... ngodi Hinh LUdiphdn tdvd dieu kien hien trongphdn tich Hinh 2, the hien md hinh dupe sfl dung TRU''CfNG DIEN T C VA THONG LUONG NHIET P H A N B T0C THOil TRONG GIA cho phin tich Cudn day bang dong,... tren tam thep cung ed gia tri khae nhau, tflpng flng b^- BS rdng viing dnh hitdng nhiit /i|, Chilu sdu vdng dnh hUdng nhi(t Hinh Kich thUdc vitng dnh hUdng nhiet tdc tiidi tronggia nhiet cdm dug
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