GROUP 8 REPORT TOPIC heating iron bars with heat

GROUP REPORT TOPIC: Heating Iron Bars With Heat Contents Global Definitions Parameters Model (mod1) Definitions Geometry Materials Induction Heating (ih) Mesh Study Frequency-Transient Results Data Sets Tables Plot Groups Introduction This is a simulation inspired by a high-rise kiln Here, we use induction coil and metal ingot to perform the simulation The heating process for the workpiece is based on the phenomenon of electromagnetic induction The current induced in the coil generates heat, and as the temperature increases, the conductivity of the copper wire also changes Heating caused by induced current is called induced heating One challenge in induction heating is that high currents in the induction coils require active cooling This can be achieved by emptying the coil conductors and circulating water inside Even for a rather modest flow rate, the coolant flow becomes highly turbulent making heat transfer between the conductor and the liquid very efficient This model illustrates a simplified water cooling model based on the assumption of turbulent flow and instantaneous mixing For mechanical support and electrical insulation, the cylinder and coil are embedded with FR4 composite material Model Definition The system to be solved is given by jωσ( T )A + ∇×( μ-1 ∇ × A) = ρCp ∂T – ∇ × k T∇ = Q (T,A ) ∂t where ρ is the density, Cp is the specific heat capacity, k is the thermal conductivity, and Q is the inductive heating The electric conductivity of copper, σ, is given by the expression σ¿ [ ρ (1+α (T −T o))] o Where ρo is the resistivity at the reference temperature To = 293 K, α is the temperature coefficient of the resistivity, and T is the actual temperature in the domain The time average of the inductive heating over one period, is given by Q= σ| E| The coil conductor is cooled by a turbulent water flow in an internal cooling channel This is emulated by a combination of a high effective thermal conductivity and a homogenized out-of-plane convective loss term: dM C (T −T ) dt p ¿ Qc = πrA where dM is the water mass flow, Tin is the water inlet temperature, r is the radial dt coordinate and A is the cross-section area of the cooling channel Global Definitions Parameters Parameters Name Expression Description I0 2e3[A] Current T0 293[K] Reference temperature r0 1.754e-8[ohm*m] Resistivity at T=T0 alpha 0.0039[1/K] Temperature coefficient Rc 5[mm] Cooling channel radius Ac pi*Rc^2 Cooling channel x-section Mt 1[kg/min] Cooling water mass flow rate Tin 10[degC] Cooling water inlet temperature Model (mod1) Definitions Coordinate Systems Boundary System Coordinate system type Boundary system Identifier sys1 Geometry Geometry units Length unit m Angular unit deg Materials FR4 (Circuit Board) FR4 (Circuit Board) Selection Geometric entity level Domain Selection Domain Copper Copper Selection Geometric entity level Selection Domain Domains 2– Water, liquid Water, liquid Selection Geometric entity level Domain Selection Domain Induction Heating (ih) Induction Heating Features Induction Heating Model Electromagnetic Heat Source Boundary Electromagnetic Heat Source Axial Symmetry Magnetic Insulation Thermal Insulation Initial Values Induction Heating Model 10 Induction Heating Model Single-Turn Coil Domain Temperature Heat Source Mesh Mesh 11 Study Frequency-Transient Mesh selection Geometry Mesh Geometry (geom1) mesh1 Physics selection Physics Discretization Induction Heating (ih) 12 physics Results Data Sets Solution Selection Geometric entity level Domain Selection Geometry geom1 Solution Value Name Solution Solver Model Save Point Geometry Revolution 2D Data Name Value Data set Solution Revolution layers Name Value Start angle -90 Revolution angle 225 Cut Point 2D Data Name Value Data set Solution Cut Point 2D Data 13 Name Value Data set Solution Cut Plane Name Data Value Data set Revolution 2D Plane data Name Value Plane type General Advanced Name Value Space variables {cpl1x, cpl1y} Tables Evaluation 2D Interactive 2D values Evaluation 2D y x Value 0.0595 0.00386 -9.64579e-4 0.0426 -0.00278 1.56605e7 0.04657 0.00285 285.04896 0.03156 -0.03309 376.20051 0.04909 0.00164 285.00361 0.04991 0.00246 284.99955 Evaluation 3D Interactive 3D values x Evaluation 3D y z Value -5.55112e-17 -0.03553 0.10362 22.52961 14 x y z Value Plot Groups Temperature, 3D (ih) Time=6000 Surface: Temperature (degC) 1D Plot Group Point Graph: Temperature (K) Point Graph: Temperature (K) 15 2D Plot Group Time=36000 Surface: Temperature (K) 2D Plot Group Contour: Temperature (K) Surface: Temperature (K) 16 ... level Domain Selection Domain Induction Heating (ih) Induction Heating Features Induction Heating Model Electromagnetic Heat Source Boundary Electromagnetic Heat Source Axial Symmetry Magnetic Insulation... Evaluation 2D y x Value 0.0595 0.00 386 -9.64579e-4 0.0426 -0.002 78 1.56605e7 0.04657 0.00 285 285 .0 489 6 0.03156 -0.03309 376.20051 0.04909 0.00164 285 .00361 0.04991 0.00246 284 .99955 Evaluation 3D Interactive... increases, the conductivity of the copper wire also changes Heating caused by induced current is called induced heating One challenge in induction heating is that high currents in the induction coils